ok, greg is technically correct in his explanation, but, i had to stop reading after the second sentance... BORING!!!!!
hehehehe
Imagine you are drinking soda.... and the glass is filled to the brim/rim and you suck just enuf to feel the soda on your lip... the glass volume/level will drop, cause there is soda in the straw...If you quit sucking, the soda will flow backwards back into the cup/glass and fill the glass up to hwere it was and it wont overflow...
The problem with our tanks is that it is slightly different then that story above, in that the sucking action, is actually the nozzles that spray the water out into the display tank.. those nozzles are an inch or more below the water surface...
So, lilke greg kinda said, when the power fails or the pump quits working, the water will flow thru the straw, i mean plumbing/tubes/pipes until the water level is at or below the nozzles inside your tank...
You kinda need to figure out how much water that is... you can use math... or you can do it gregs way and hope you dont over flow the sump....(you shouldnt if you start off with really low water level in the sump, as greg said, fill just until the water is above the pump...)
The problem with this method is that by the time you are 'experiemting' and figurin', it is too late.. you already have the sump in place and i doubt anyone would pull it out and relocate baffles...
to figure out how much water will backflow to the sump, you have to figure out how many inches below the water surface the nozzles/inlets are...
lets say 2 inches...
lest say your tank is 36x18..... then you need to do the math to determing how many gallons equals one inch...
there are tank voume calculators all over the place but the math is as follows (lxwxh)/231
so 36x18x1 = 2.8 gallons PER INCH
So, you can expect about 5.6 gallons to backflow... I would round up to the next gallon or try to figure out how much water is in the plumbing, and to over estimate to be on the safe side.
this means you need 5-6 gallons of room/space ABOVE the baffle nearest the pump...
you would do the same math... but this time measure from the top of tank to the top of baffle nearest the pump...
This figures that the pump might fail RIGHT AFTER A WATER CHANGE or AFTER A WATER TOP OFF
which would be the worst case scenario... but chances are it willfail after the water level has dropped a bit giving you a little more tolerance...
You can also do some math to figure out the height of the baffles, or the height of the sump, or the size of the 'compartments' to make sure yo uahve enuf room for the skimmer, and a refugium, and figuring out how often you will need to top off...
i.e the bigger the compartment is that the return pump sits in, the more time/days you can go without TOPPING OFF
I have seen some sumps that can not survive a day without top off... so they ABSOLUTELY needed a working/reliable auto top off system... that or they had to make sure they filled thier sump before going to work each day..
so the quandry is (The goal), to create a big enough RETURN section, while keeping the minimul sized skimmer section, (big enough to fit your skimmer, or maybe your future skimmer), and get a reguium that is big enough to be effective...
also, the baffle placement needs some consideration too.. they have a three baffle system, usually referred to as a OVER UNDER OVER baffle system.. bascilly the water goes OVER the first baffle, then UNDER the second baffle, then OVER the last baffle.. this is to reduce the chance of bubbles being swept thru the sump and back into the display tank...
typically bubbles float to teh top... but if the water flow is too fast, the bubbles can get swept into the current and OVER the baffles...
to minimize the flow/current in the baffles you need to think about white water rafting...
big rivers barely look/feel like they are flowing, when the rivers are big and wide... but when the walls of the canyon get closer the water rushes through them ...so it is with baffles.. if you placed baffles within too small an space, the water will rush throu them, the water level will be a bit higher over the baffles, and the chances of air bubbles and noise is greately increased..
I reccomend at least 1-1/2 inch between baffles... this means 3" of space is 'lost' in baffles, so if you have a 14 inch sump, at least 6" will be for baffles if you ahve THREE COMPARTEMENTs, two sets of baffles...
you can maybe see where space is a premium and math and planning and sketching is vital for a good final product..
anything less then that effort is basic chance that things will be ok...
ok, so my message wasnt much less BORING then gregs... sorry