For the full Intelliflow vs. 4x160 decision, they do not have the same cost savings unless your situation is such where all of your programmed features have a fixed and known amount of time. In that case, you can try and figure out one turnover of water per day spread out over time in the most economical way and that will be the same for both pumps. If you have no features at all and only need one pump speed, then the 4x160 will do just fine.
However, if you have any sort of dynamic feature situation, such as a solar system that requires higher GPM (and it sounds like you do), then the full IntelliFlow will usually be more economical since it will turn off the pump when a full turnover has been reached (assuming the "feature" is off -- i.e. that you don't need further solar heating). With the 4x160, the pump doesn't keep track of the fact that the high GPM feature has met your turnover requirement so after the feature turns off it keeps running at the low GPM rate (you can only set the RPM and have to guess or figure out from pump charts what the GPM is).
The full Intelliflow will also ensure that the GPM is maintained, and therefore a full turnover is achieved, even when your filter gets dirty. The 4x160 is more likely to have its GPM rate slow down as the filter gets dirty (since its RPM is what remains constant) so you could end up with less than a full turnover of water and have to adjust for that manually by monitoring your filter pressure and doing the calculations. Of course, this difference in GPM may not be very big so is probably not something to worry about.
The Rainbow 320 injector is used to inject chlorine (typically dissolving Trichlor tabs) into the water, so is that something the pool builder always has operating? I wasn't clear if "backed by" meant "augmented" or "used in conjunction with" or if it meant "backed up in case of failure?". An ozone or mineral or combination system still requires chlorine in the pool, though the amount can generally be lower (this is also true for an SWG where the chlorine level is typically lower than in a non-SWG pool). Since you have to have some chlorine anyway, I'm not clear on the benefits the pool builder sees from having an ozone system plus minerals in the water when chlorine alone will work well. In fact, if you put in a peristaltic pump feeder to inject chlorinating liquid or bleach, then you'd have an automated system that could use chlorine alone and not face the buildup of CYA that normally occurs with use of Trichlor tablets.
[EDIT] In my own pool I have an electric opaque pool cover that is kept closed unless the pool is in use and this makes the chlorine consumption very low, about 0.5 ppm FC per day in a 16,000 gallon pool. I usually only have to add chlorine twice a week because of this. I expect that you will see similar low consumpation due to your cover, though your pool may be 1.5x larger so might have 0.75 ppm FC per day consumption. [END-EDIT]
Richard
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