Well, I had a fun night. About 2am last night, my Dad wakes me up, "Hey something is leaking... a lot." Lo and behold, the stand and area around the sump is full of water, as well as most of the tile hallway. A good chunk of water also soaked into the nearby carpeted living room. We unplugged everything, then started toweling up what we could. I ran a blow dryer under the stand, and seem to have dried it out pretty good without too much damage to the stupid particle board base from all-glass. The carpet might be a different story. We pulled up a few feet of it, and the foam pretty soaked. Some of the water also wicked under a wall and into the adjacent room. Dried what we could, and have fans and a dehumidifier running in the living room. Gonna have to better assess the damage after work.
So what happened? Well the modified beananimal didn't fail, the emergency overflow was bone dry, and the level in the display hadn't gone up. Turns out a filter sock was to blame. I had read interesting things about milk filter socks, and decided to try some of these.
http://www.fleetfarm.com/catalog/product_detail/fleet-farm-brands/farm-livestock/milkhouse-brand/milkhouse-brand-heavy-duty-milk-filter-socks-2-1-4-in-x-12-in
Well they work a bit too well I guess. I didn't rubber band or tie it to the drain at all, just slipped it over the siphon pipe. Turns out, once it got going, the water flowing over the top was just enough to trickle onto the rim of the sump, and over the side. I took out the sock (which had turned a lovely shade of brown in just 4ish hours) and problem solved. Either I have way more crap in the water than I thought, or these filters just work really good. I am going to see if I can trim one down and still run the filter that way. Amazing how a n $0.08 nothing can undo the best of plans.
All in all, I needed almost 5 gallons of saltwater to get the water level back up. I'm not sure how full the auto top off container was, but it had about a gallon still left in it, so no more than 4 could have been pumped into the sump. So 5-9 gallons on the floor in total. Thankfully, the waterblaster didn't run dry, in fact the small amount of air it was pulling in was what drew attention to the problem. When I get my reef angel hooked up this weekend, I'm going to have to think about how to set up the ATO and float switches. Might need one as a low sump level alarm trigger.
Thank god for insomniacs! Gonna be a long day of work though....