I was using the brochure data but the manual is much better data and yes I get 92 GPM from that as well.

I can only find the energy usage curves for the Intelliflow. Are you assuming they are the same for the 4x160? I would check with Pentair on that to make sure they are the same.

Ok so with updated information, I plotted your plumbing curves (solar off/on) on top of the pump's head curve. Where they cross are your operatng points. I assumed your pump was at the same elevation as your pool.



You would get the same answer if you simultaneously solve your pump equation and your plumbing equation. So the crossover points follow the relationship of GPM = .0325 * RPM for solar off which is pretty close to what I had before. For solar on, the crossovers occur at GPM= .02 * RPM.

The only way to change your operating points is to change your plumbing. Otherwise the efficiency is what it is at those points. However, it does sound like you have an issue with your solar so if you are able to fix that it should move that curve to the right increasing the overall efficiency with solar on.

Good luck.