Sometimes you get very small amounts of air leaking in at the joints, occasionally you will get salt creep around it which is a tip off but a lot of times you have no idea how the air is getting in.
My other question is how big is your sump. I have found that trying to push a lot of water through a sump is a good way to get microbubbles in the tank, do you have baffles in the tank, do you see bubbles in the section where your pump is pulling water. If that is the case the only solution I know of is to cut back the amount of water.
In all my future tanks I will be pushing minimal water through the sump (less than 1000gph in a 50gal+ sump) and using closed loops and pumps for water circulation.