I fixed the air in U tube problem. My box was rated at 800gph and it had a 1'' U tube, but my air pump only pumps 317GPH and it pushes upwards so it is probably more around 200 to 250GPH. So WAY under my overflow boxes rated GPH. The problem was, the water was going so slow through the U tube that any air bubbles that got in it, would stay in it, and float to the top, eventually growing in size and eventually causing the siphon to fail.
I figured higher flow would make water go through the U tube faster, and perhaps blow those bubbles out so there is no problem with bubbles. I didn't have a larger pump at home to increase water flow, so instead I used a smaller U tube. In place of the 1'' U tube I now use a 1/2'' U tube. Being a 1/2" U tube this will lower the GPH rating of my Overflow box. But like I said it was rated 800GPH with the 1'' U tube, so I would guess with a 1/2" U tube it is around 400GPh, still way above the 250GPH max I am running.
Anyways, with this smaller U tube in place, water rushes through it much faster. Now any small/micro bubbles that get into the U tube go straight through, quickly, and out the other end. In about 3 days my OLD 1" siphon would have a quarter sized air bubble at the top. In about 3 days with my NEW 1/2" siphon(U tube) I have ZERO air bubbles. This seems to have completely fixed my problem.
So if you are having bubble issues in your U tube, either increase flow, or get a smaller sized U tube, just make sure when you re-setup with the new U tube that you watch the flow and make sure the overflow box can keep up with the pump with the smaller U tube.
I have a video showing this, and other aspects of my tank/sump, if you would like to see it, along with some other videos of my fish setups, please visit
www.youtube.com/earthling1984