Marty,
I built a T into the return line in anticipation of any problems with the drain vs return. I actually have the return divided into 3 separate areas, each with it's own ball valve: 1) back to the tank, 2) feeding a small refugium, (which is a partitioned part of the sump, the refugium drains back into the sump via a pvc overflow), and 3) returning to the main sump area. I tried running some water back into the sump however the result was that it allowed me to further open the valve feeding the return pump but it still didn't provide a constant with the sump level over time, (again dealing with the evaporation problem).
Mike,
I check the SG after I add the additional gallon of RODI water and I rarely have to make an adjustment. I never checked before I added the water, I assumed that if only water was evaporating, not salt, then the SG would rise if you did not replenish. If I added saltwater then I assumed the SG would also rise, (unless I was performing a water change).
I guess my options are: a) deal with it, b) get a less powerful pump, c) get a bigger sump, d) try changing out the 3/4" pvc for 1/2"pvc as per Bill's suggestion or e) add a top-off system.
I tried to build a system that was all inclusive, that's to say that the sump/refugium and all equipment was contained in the tank and or stand. (We'll see how long that lasts).
I don't see how the drain could ever perfectly equal the return unless both were exactly the same gph, (and you still would have to deal with evaporation unless you had an auto-top off system).