I just got a AquaC ev240...just a little large version of the same model, but it took mine nearly two weeks before it did anything. I did get the larger pump (AquaC recommended a Mag12 or Mag18 - I got the 18). I have a ball valve on the line, but it is wide open. The air intake is wide open. It is now producing dark green smelly stuff after initially producing some pale, watery stuff for a few days.
So you've had it running for a year... that sorta rules out break in issues. I'm guessing you don't run the calcium reactor or the ozonizer through the skimmer, also. I'm assuming you've adjusted the gate valve so that the water/foam level is at the recommended level. That being done, I think you can adjust (turn down) the air intake to get thicker skimmate. Good luck.
Bubba
P.S. Have you given AquaC a call or sent them an e-mail? Most companies in this hobby are more than happy to discuss problems and advise...



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