Without a Bypass the T'stat can throttle from No Flow to Full Flow, so it can control the temp in a more stable and better way than if some of the flow by-passes the T'stat as that portion of the flow the T'stat has no control over, so in regards to claimed 'hot spots' it is more likely to occur with a by pass than without, though with or without, hot spots won't occur because of any perceived flow , more like because of turbulence or blocked flow paths.
Yes, too high a spinning impeller will also cause cavitation, however the impeller size used on these engines is small enough that they can be spun up to to fairly high speeds before cavitation occurs (I think my Pump friend said 5 800 - 6 000 shaft RPMs - without the bypass and pressurised to 0.8 bar), the by-pass while increasing the on-set of cavitation, isn't the only cause of it. The A plus engines we got out here were all fitted with the same size pulley as the earlier engines, in fact, I have been looking for the bigger pulleys but can't find one! They are very rare in these parts. The bigger pulley was fitted mainly to reduce noise as this was an issue in some of the European Markets. One other item that great reduces the likely hood of Cavitation is having a true Header Tank, so that the major part of the system is devoid of air.
To the guys who want to say this causes hot spot and other things, I have tried systems with, without and also 'part' (ie drilled T'stat) By-pass. Without doubt, I have found that a by-pass less system on these engines the way to go - hands down. If you haven't tried it, in a proper way and test method, then please don't knock it.
Edited by Moke Spider, 20 June 2015 - 10:38 AM.