Are there any bubbles forming in/under the algae? Sounds like dinoflagellates. You will just have to keep syphoning and doing water changes till they get under control. Part of the reason all of the params "seem" ok is because the nitrates and phosphates are locked up in the algae. Look at what your doing very carefully, what you feed, hopw much you feed and any supplements you use. Somewhere it sounds like yopur getting too much nutrients ionto the water column/tank and it's fueling the
algae bloom. What are the actual results of the tests? "Within range" is not a good identifier to use to help determine what the problem might be.