I need help tuning a 2 stager

[Xenogias]

Sounds like both stages are very badly undercharged.

1st stage with R507 should be at ~160 psig @23C

2nd stage only has enough charge to produce liquid to cool the CPEV head? Ha! that's not much at all.

The good news is that it seems the leak is big enough, maybe it was made bigger by running it? so that the performance has seriously degraded since your first post. Maybe your HVAC guy can find that leak? That's the first thing to tell him, you have leaks on both stages, no point in going further until those are fixed.

I'm not convinced the 1st stage has a leak as I remember it being charged to that before. It's currently at 80psi static... Are you sure 160 is more normal?

I was hoping to avoid tearing off all that insulation but I'm going to do it on the 2nd stage so I might as well on the first.

Also, I just pulled some of the insulation off of the line from HX-->CPEV and from CPEV-->liquid line of evap and there is a fine white powder over the inside of the foam--like talcum powder. Is this normal of some insulation foam or have i found evidence for the leak?

Also, for correctness sake the fittings on the CPEV are brazed, not flare...