Thanks again. I will be there again tomorrow to check it. The drain is 1 1/2" with a gate valve,... and 2 90 degree elbows to get through the cabinetry and into the sump. What kind of issues should I expect?
I believe the drain is the right size, but now I think we're getting to the crux of your problem. A drain with bends and elbows, etc. is backing up, then allowing flow, however subtle it may be. If you're going to have that long of a run and can't redesign it to empty on a straighter line back into the sump, then you're best bet is to tee off about 6 inches in front of the gate valve (which should be as close to the skimmer box as possible) and install an air vent pipe facing upwards. This doesn't have to be anything fancy. A piece of pvc about 10 inches long facing up from the T will suffice. Basically, this "vent" will allow water to flow more easily without putting back pressure into the black box. This back pressure can cause the water level to rise, fall and repeat with every rising foam head. It's an annoying problem, but easily corrected once you understand how these skimmers work. Air must be coming into the skimmer via the injector at the top of the tower, and have an exit point which is the vacuum created by the waste line to the remote collection cup. These two holes act to create suction that pulls foam up through the skimmer. If water cannot freely leave the black box at the gate valve setting you've chosen, this will no doubt cause surging and poor skimmate production because the water level will in the skimmer will never stay constant. With this added vent pipe, the water can freely flow back to the sump with the elbows creating minimal friction due excess air having an exit point out the vent.
I've probably encountered almost every problem there is to have with ETSS. My 5 rules are:
1. Replace bioballs yearly
2. Once the skimmer kicks in, set the gate valve and never touch it again.
3. Clean the skimmer cup and neck only when you can't see through it anymore. This is usually once every two weeks for me.
4. No elbows if possible on drain lines.
5. Always run pump on full throttle and make adjustments from the gate valve back to the injector. Running the pump at full throttle is the way the skimmer was designed to work. Throttling it back to achieve the correct setting is the wrong way to adjust them.
These skimmers are beasts once you understand a few things that can make them temperamental. Correct those and they truly are to be left alone until they need cleaning. Hope this helps. I really believe we've found your problem this time.