Quick update for those interested...
I contacted Ecotech, the North America distributor for the Clarisea to report the problem and it proved to be less than helpful. Technically I do not have the Clarisea 3000 Gen 2. I have the GEO sump that integrated the clarisea filters into the sump. When Ecotech support realized this, they immediately dismissed my problem and instead of being helpful, went on to blame GEO for their design...
Now in defense of GEO sumps... I know for a fact that their auto roller sumps are good because they worked perfectly fine with the clarisea rolls, I went through 5+ rolls worth of operations without a single issue. But when I replaced the last roll with the XL, the problem started up.
The motor side doesn't seem to be an issue since it's been working. I tested the clean roll side to see if the cardboard core was damaged and it was not. I checked to see if the clean roll was rolling freely or stuck, it's rolling freely. There is no debris inside the unit because I literally cleaned the sump 2 weeks ago and i visually checked again.
I did more research and I found that some people run into issues with rolls stretching when they try to use third party rolls they source from Ebay (probably because some rolls are made with material that is stretchier than others). Another user with problems with the XL roll seemed to suggest that the motor handles the XL roll differently, almost as if the motor was originally design for a certain amount of new roll (size /resistance).
I'm going to continue troubleshooting, but I'm a bit disappointed that Ecotech was so suick to dismiss my problem. It's not like the clarisea is a car or space rocket where even the slightest design change can mean it works or it doesn't. It's just a bunch of acrylic pieces with holes in different places with a motor... If my sump worked with the regular rolls, why would it not work with the XL...
Anyone have a direct contact to D-D that might prove a bit more helpful?