Running 4 xl 6.6 gallon pots on a 12 gallon res tank using Humboldts secret nutrients ATM. Coco/petite 60/40
Had some of same issues, floats stuck, bad wicking, nutes separating in res tank during veg period.
Floats sticking I found was a problem with certain nutrients being added...mainly plant enzymes (Humboldt) after it sits waiting to be used in the lines/floats it films up and causes gunk to build up. Going to run organic amendments next as a test, only ro ph'd in tank
Wicking issues I had only when I ran without the air bases, think I had to low of a perlite ratio there also, have adjusted and no problem since.
My nutrients separated during veg in the res tank also. Placed a small hydro pump in bottom of tank, keeps it circulated... But in the future during veg there is no reason to fill that reservoir tank completely. I wasted a lot of nutrients doing this, after about a week when the four plants hooked up to it had only used about two and a half to three gallons and were growing great... I had to dump the rest of the water out because it was getting a biofilm in the reservoir from the pump circulating it. I didn't want to risk root rot.
All in all is a great system once you get it dialed in for your environment.