joe, i am not an expert in pool systems but i know my in-floor-cleaning-system (ifcs) system extremely well. So, bear with me...the photo shows a t after your chlorination device. From the photo i cannot see where that other side goes (is it capped off?). I assume one side goes to your cleaning manifold via underground and the other side goes? (nowhere if capped). Was there ever a valve at that juncture to your knowledge?
Jk: One side of the t goes to the cleaning system and the other goes to the aerator. There is a valve to turn off/on the aerator.
Do do you have any wall return fixtures? If you do, how are they fed? My understanding is that in some ifcs systems, the wall returns are fed by one of the ports out of the cleaning manifold. Apparently some ifcss have no wall returns. Which is the case for your system?
Jk: There are two wall returns in the ifcs.
Your popups apparently work after replacement but there is a reason that all of us with ifcss keep asking about pressure...it is one of the key components to the proper operation of the popups. Based on your numbers (and understanding mine), i still think your system has an issue that did not exist when you had your previous pump installed...something has changed...it’s also possible your psi readings have an issue as bama rambler hinted when he asked about your gauges readings when stopped.
If your system really does require your pump to run at full speed to get the pressures you are stating...then it is a very poorly designed ifcs and would be a poster child for why ifcss have a poor reputation on these boards. I received a lot of help from the experts and other users on these boards when i started an ongoing process of experimenting with my ifcs. If your previous pump showed a psi of close to close to 30, your current pump should be able to get close unless, as i stated before, something else has changed. I suspect your new popups are just baaarrrely working...and you will have future problems if you don’t find the real culprit for your ifcs problems.
Jk: Not sure why the psi dropped so much after i replaced the pump. I believe they both have similar specifications (2hp, 3450 rpm). Gpm on the new is 97 but not sure what the old one was.
I don’t think your ifcs is a poster child based on the fact that you told us your previous pump gave pressures close to 30psi at the filter. So keep working with us if us if you think something is still not right.
A final couple questions...from the photo i am not positive what size your piping is...is it 1.5” or 2”...including the 6 zone pipes exiting the bottom of your valve manifold? Were the t-valves you replaced the 2” or 1.5” versions.
Jk: Piping is 2", not sure what the size is from the cleaning manifold as they are not visible. I agree the pressure is marginal. Any advice on how to increase the pressure is appreciated.