@mbmit,
it probably is undersized at 1/2 cube of resin. As far as the part with the tabs broken off, something caused them to break, usually it's the tab on the outer case that breaks( this tab keeps the injector from moving sideways) and then the injector moves and the tabs on the injector drive gear break off from too much stress. The entire outside case and the injector drive gear probably both need to be replaced. Since they are under warranty, I would call the dealer aand ask about a bigger tank with more resin, and fixing the parts under warranty. The service call may cost a little more, but since it's not an electrical problem, they should be able to fix it in one call and no need for an "upgraded" head. Unless you have the airmaster(uv system on the furnace), r/o and carbon tank in front of the aqc, there is no need for all the extra bells and whistles. Just remember that you electrical portion is out of warranty(10 years) , but the rest of the system has a lifetime warranty. You do have to pay for the service call though, and extra for a bigger tank and more resin.