Thanks guys for taking the time to read my post. I do have pressure relief valves on my tank and also a open parrot with product coming out. But I had not put one on the reflux tank. It is a closed tank, due to vapor I would believe you would have to in order to be safe. I thought the same thing about the float sinking. The float used is a 24 volt mechanical pencil style float. It is connected to a 24 volt switching system. Pumps are switched via the switch with 110v. That was my first thought (pressure building and holding it down). I just was trying to figure out how it was happening and how to eliminate it. But I'm not positive. I hadn't thought about the proof causing it to sink. That's a good idea, but it should not have that high of proof in the reflux unless a vacuum was pulling vapor down. At least that is how my non engineer brain thinks. Each column is 12in, each has a 3/4 in reflux piping and individual p traps with inline one way swing valves ( non spring loaded, flapper style). On the holding tank the reflux enters in through the top and the pump inlet is always submerged. The pump outlet also has a one way valve in the return line. The switch is a mounted via a tri clamp through the side. It has a short throw (up and down float level may 2.5 inch.) so to eliminate any chance of creating a hydrolic cylinder when triggering the pump. I have verified that everything's does function. Just not correctly during the run.
For now I am putting a one inch blowoff line on the tank with a bucket of water ( simple air lock like a fermenter) to see if that will fix the problem. I wish I could run a vent line but I can't get it to the roof without major work. I plan on running it tomorrow and I will post if that works along with pics.
Any ideas are greatly appreciated! Thank you again for taking the time to reach out. - Brian