The overflow box has a little cap over the 90 so the water has to flow down the sides if that makes sense. It was the 700gph from glass holes.Your overflow is not getting a full siphon so you are trapping air on the way down that creates the bubbles and foam in the sump.
The basement sump creates a different issue since you now have a much longer vertical drop.
What size is your display tank, sump and return pump and how is the return plumbed? Sounds more like the return is not large enough to keep up with the siphon on the overflow so you are getting trapped air down to the sump.
Do you have any photos or a description of your standpipe arrangement inside the oveflow box? Is there something on the 90 degree elbow inside the box such as a Stockman standpipe so you suck water with a measured amount of air versus surface skimming with unlimited air?
It starts at 1.5 and then reduces to 1" a few inches below the 90. I didn't want to drill a 1 3/4 hole through the plate in a main support wall of my house therefore the reduction to 1"