how is it that your sump is overflowing? what you are explaining is impossible. the return pump pushes exactly the amount of water back to the tank as what comes in the sump. it's what dictates the amount. if you put a smaller pump on the tank, less water will come down to the sump. if you put a larger pump on the system, more water will come into the sump. what valves are you talking about opening up fully? do you have ball valves on your drains? if so, yes. they should be open all the way. if you want to slow down the flow from the tank to the sump or back up, you want to choke back the pump itself, at it's exhaust port.
as for the koralias v.s. the vortechs, they are going to do the same thing. swapping them out is not going to solve your issue, although i don't understand why you would want to solve it. the powerheads are doing precisely what you want them to do- keep detritus suspended until the filtration has a chance to remove it. you don't want anything to settle.