The tank has a volume of 540 litres plus about another 80 litres volume for the sump giving a total system volume of 620 litres, knock off around 100 litres for water displacement from the live rock and I have a working volume of 500 litres. When calculating the water turnover through the sump I work to a ten times turnover of water through the sump per hour, this means that for a 500 litre system you should move 5,000 litres of water through the sump and back to the tank each hour.
I wanted to use a submersible return pump rather than an external one so I went for the largest submersible Ocean Runner pump the OR6500 which would deliver a water flow rate of close to 5,000 litres per hour at the head height of 1.35m that I had. This would give me close to the ten times per hour turnover through the system that I wanted.
I also needed drainage piping running from the main tank back to the sump that could deal with a flow rate of 5,000 litres per hour. I use ABS rigid piping for my plumbing and for the return drainage use a size of 60.3mm outer diameter which can easily handle 5,000 litres per hour through it.
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Personally I always use a system where the base of the tank is drilled and utilise a standpipe to set the water level in the tank. I do this for a number of reasons, by having the base of the tank drilled with a standpipe fitted rather than an overflow hole drilled into the side or back of the tank close to the water surface I am reducing the risks of the drainage system blocking and causing the tank to overflow. I rarely, if ever bother with weir systems built into the tank, I don't see any advantage to them and they take up a considerable amount of tank space without any real benefit. In this tank the standpipe is plumbed into the rear left hand corner of the tank.
One of the problems with systems that have drainage running to sumps below is how to stop fish and other animals getting sucked down the piping. To solve this problem I made a baffle out of egg crate that fits around the top of the standpipe and prevents any fish or snails ending up in the sump.

When running the water flows down the standpipe and into the first section of the sump and in this first section I placed a fairly large volume of bioballs. These bioballs were not to act as biological filtration, bioballs and the like do make very effective areas for colonisation of aerobic bacteria but only when they are run in large trickle-style systems. The surface area of the bioballs is not that large (in comparison to other media) and when submerged they are not a particularly effective filtration media. The reason that I used the bioballs in this section is two-fold. Firstly gaseous exchange, when the water enters the sump the water exits the pipe runs over a trickle tray over several inches of bioballs that are built up above the surface of the water. As the water passes over the bioballs it is split into tiny droplets that greatly enhances the gaseous exchange between the water and the atmosphere. This is very important as it allows soluble gases such as carbon dioxide and nitrogen to be released from the water into the atmosphere and without it you are relying mainly on items such as your protein skimmer to provide places for this gaseous exchange to occur. This gaseous exchange helps to maintain a higher pH as carbon dioxide gas is released from the water readily and the water is sure to be oxygen saturated once it has passed through this section.
The second reason for the bioballs is to act as a bubble stop. As the water plummets down the drain piping and is churned around it develops large amounts of minute micro bubbles that can easily flow through the sump and be pumped back up into the main tank. These micro bubbles can irritate your corals causing them to stress and release mucus and in addition the micro bubbles can be very unsightly. The bioballs help to prevent the micro bubbles from entering the next section of the sump.

The return pump is plumbed in with rigid ABS piping with an outer diameter of 33.4mm. A T-piece was inserted in the piping just above the pump that leads to a hosetail fitting so that at a turn of a valve water can be pumped out of the system for water changes. The return piping was also fitted with ball valves to control the flow of water back up to the main tank.
The return piping was split into two outlets in the main tank, one in the top right hand corner of the tank and the other in the top left hand corner. One of the safety aspects needed to be incorporated into the plumbing was to ensure that should the main pump ever fail then the water in the main tank does not back-siphon into the sump causing it to overflow. To prevent this happening the two water inlets in the main tank are positioned close to the waters surface so that should the main pump ever fail then only a limited amount of water can back-siphon into the sump.
For water movement in the tank I have two Seio Superflow pumps that have a flow rate of 10,000 litres per hour. This gives me a total of 25,000 litres per hour water movement in the main tank which is 50 times the volume turnover.