Gentlemen (and Ladies)....
I am proud to say that I....Paul...am an idiot.
So, after talking to my father in law who got me on the right path regarding the pump output...it got me thinking. I remember reading somewhere in the previous 350 pages, that Uncleof6 mentioning that 3/4" tubing on the return will constrict it and you will lose quite a bit of output.
To give you an example, I used 3/4" garden hose (6') section to test my overflow. On the Home Depot Flotec return pump, I got crazy flow. The emergency kicked in and shortly thereafter the siphon kicked in.
Tonight, using that same garden hose, I tested it on the Sicce pump, and timed it. It took 12 minutes for the main siphon to take over, the emergency stayed dry. It took another 22 minutes for all the air to purge out of the pipe. Why? Because I had my gate valve literally 1.5 turns from full close. No wonder it took forever to purge the air. I had to dial it back to match the return flow.
I was on my way home, and I was thinking about calling BRS to reem them out, when it dawned on me that I have 1" piping that I'm going to be using. That's when I remembered what Uncle posted (contrary to popular opinion, I actually do read what you post Unc).
I attached the 1" PVC piping (ie: jerry-rigged it). Just loosely fit. The first time, it blew apart, and thus showed me why I was testing in the garage, not the house. Wetness and 30 degree temps. Not good or cool (no pun intended). Attached things tighter. Ran it. Emergency kicked in, had to open the valve up to I am estimating about half way. Siphon started. shut off the system and restarted it again. Emergency kicked in, main siphon took over after approximately 1 minute, and final air purge in like another 30 seconds or so.
I didn't have a leak. I did do this right. The problem was the return pump output tubing size.
yes, I'm an idiot. Yes, it's silent. took about 5 minutes to get it dialed in.
Did I say I'm an idiot?
I have asked for help about 100 times in this thread. I've received an answer about 30 of those times. I appreciate the help, and Uncle, next time you're in Delaware. Beer is on me. Thank you for your patience.