Thanks for the tips Randy..I'll give it a shot.
Also from Steve at AquaC (quick response)...more advice, I'll let know if they work out.:
Hi Jeff,
Thanks for the message, I can help you out. Because the skimmer is overflowing with wet foam, it sounds like it might be reacting with something in the water - usually an additive, supplement or water conditioner. Let me know if you're using any of these.
As far as the skimmer's inconsistency, I think that there might be several factors involved. The pump you're using is a bit strong for that skimmer, and may need a valve to allow you to throttle back the flow. However, the water level within the skimmer sounds a bit low as well (we now recommend running the water level in the foam tower flush with the top of the black box - I've attached a copy of the updated manual). From your description, I think that water is siphoning from the skimmer, causing a lower level than what is expected with that pump. I think that there are a few different variables affecting the skimmer that are counteracting each other, which is why the skimmer is running so inconsistently.
The first thing I would do is to put a valve on the flow side - assuming that the pump hasn't lost any pressure over 5 years of use, it will deliver too much flow for optimum performance, and needs to be turned down a bit. On the skimmer output, I would either use a tee fitting (see attached diagram) or drill a 1/4 - 1/2" hole in the top of the elbow as a siphon break. Open the skimmer's gate valve completely, then use the valve on the intake side to set the water level in the foam tower. Our previous recommendation was to run the water level even with the internal platform, but we now recommend starting about an inch higher than that, or even with the top of the box. This is 1-1/2" to 1-1/4" higher than the water level you described. From this point, you can raise or lower the water level a bit, depending on the type of foam you want to produce (wet vs. dry).
For max performance, the air valve should be wide open. Also, make sure that the hose on your drain fitting isn't submerged - this will cause backpressure, preventing foam from rising. Try that out, and let me know if it helps!