Well, at this point I think it might be a basic problem might be experiencing since you've got the same issue on multiple filters. I think you have air pocket(s) in your canister even after you primed it.
If you unplug and plug it back in after say 10 seconds, do larger air bubbles come out of the outlet?
If so, you have air pockets. I would repeatedly do this until no air bubbles come out at start up.
It might be that your tank is sort of super saturated with O2 and it's building up in the canister. Maybe turn off the air stone for a while and the filter too after the above procedure (couple hours?). Then just turn on the filter and see.
I did start the thread to get feedback so I tried your recommendation with the purg. My usual procedure after cleaning the filter; put the filter in place, fill the canister up with water, attach the lid, I have a spare hose I attach to the return to bleed the lines before attaching the actual return, let it sit for at least 20 min, attach the return, open the valves, let sit for another 20 min, plug in the filter, un plug the filter, repeat five or six times, then the filter does its auto purg.
After your recommendation I did my standard process but instead of bleeding the lines from the return I used the drain valve. I opened both intake and return with the drain valve open until I got a consistent pressure then shut off the drain and proceeded.
I'll give it a day or two to see how it works out. Such a tedious process for a filter. I just hope I held my lips right.
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