There are several common reasons a protein skimmer will overflow but the most common is a chemical reaction within the water itself. Some chemicals react with the air that the skimmer produces and causes the skimmer to overproduce foam-mate. The following is a list of items known to cause skimmers to overflow:
New rock
New sand
chemi-clean
Chemi-pure
purigen
red slime (cyano) remover
reef/frag putties (epoxy putty)
frag glues
water conditioners
fish medications
de-chlorinators
stress coat
new filter socks
newly mixed salt
bacteria (seeding) additives
high salinity
This is not a complete list of products that will cause a skimmer to overflow.
In sump skimmers: The water level in the sump - It is important that you place your skimmer in the proper water level. It is also important that the output of the skimmer is not submerged under water unless it is properly vented.
The inner water level in the skimmer body - If your inner water level is set too high the slightest change in your water chemistry can cause your skimmer to overflow. We suggest that your inner water level be set at no higher than the collar where the cup meets the body.
Blockage - The air intake otherwise known as the venturi, is like a small vacuum pulling air from the surrounding environment. Often collecting dust and debris from the air which can block the proper amount of air to enter the pump increasing the water being pulled by the pump. It is also common for salt-creep to build up in the venturi and it will need to be removed manually by scraping it away or dissolving in a solution of vinegar and water. Make sure you inspect the air venturi, silencer and air hose for any debris or salt creep deposits. Also, be sure the air hose is not bent or too long preventing proper airflow into the pump.