What I'm about to say might raise some hackles,maybe yours or maybe not but there's far too many sore toes around to avoid stepping on them from time to time. This thread could easily serve as poster child on how not to get things done. Right out of the box op asks for information he can pass along to someone he has hired. I can't explain all the reasons why this wrong but no professional in any field wants to hear what some joker on the web said. Most said what the issue is but never said how to prove or eliminate that issue. The same opinion of issue was repeated even though op had already assured that had been eliminated. The first day op posted and gave a few symptoms,someone said "If what you said is accurate (100% of first charge was still in system when evacuated and recharged) the only thing that makes sense is admittedly far fetched but here gos. If high pressure side has over pressure protection,therein could lie the answer." To my knowledge the suggested tests were never done but 2 weeks later,a part replacement and another evac & recharge it became obvious. When you consider that he said "the only thing that makes sense" and gave simple instructions for testing rather than just blurting out a possible issue and leaving it at that,you might think the guy was serious. Which brings use to sitting here over 2 weeks later "running in circles". If you think the guy just made a lucky guess,maybe he could be convinced to try his hand again. If you think the guy might apply common sense,a little science and experience to troubleshoot instead of randomly guessing,maybe look there for a path forward from here.
In summation,it's difficult to hear what is being said,much less weigh it when the whole room is shouting. Troubleshooting is about testing then using common sense to evaluate test results. As for going to the manuals,that's the first step but the manual is written with the expetation reader understands the principles and will combine them with specs. Most important,this same movie plays out every day over and over but it doesn't appear we learn anything and just keep on doing it. That's my 2 cents,spend it wisely.