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I may have overfilled it a little, but with the ability to increase the flow with the Eheim pump, I'm still getting enough movement to keep it from clumping.
I use a Tunze 9011, and know if it's not assembled correctly, after cleaning, it doesn't work properly, and as Phil said it needs to be in the right water depth. If you can get that working it'll solve a lot of your problems.
I can't tell you for sure just what my PO4 was at the time since I wasn't using a Hanna meter when I started. I don't believe either my PO4 or NO3 were very high at all. I did take my fuge and GFO off line when I started the pellets. After a few months, my NO3 was undetectable, but the PO4...
It looks like I've used about 1/3 of what I started with. I noticed a slight increase in my NO3, so I'm going to add some more today, and see if that will reduce it.
Here's the amount of pellets that have been consumed in my system over the last 9+ weeks.
First picture was taken on February 17, the second today (April 24)
Here's something I found:
http://www.co.gloucester.nj.us/depts/h/hedss/envhealth/sw.asp
I don't know that I'd be using that water for anything but black water use.