j,
My filter pressure is usually about 1 pound at 1200 RPM. Filter pressure is backwards from what most think. The lower the pressure the better the flow. The pressure you see is how much effort it takes to push the water through the filter. That said, I do not have a heater.
If you install a heater by-pass, then you should be able to run at a much lower RPM and still close your flow switch.
Have you ever cleaned your filter since the pool was built? Often during the build stage, all kinds of stuff can make it into the filter.
I went back and took a look at some of your pics. Why do you have the valves on your return side only half open? What do the two pool side valves control?
It also appears to me that you have way too much water going to your spa spillover. Your Return actuator is set for 50% spa and 50% pool..
Thanks,
Jim R.