Bill,
Since Charlie hasn't posted any pictures or sketches of his
design, I was referencing more what you'll find in auto
installations than in a/c. Still the principles are the same,
namely that the coolant naturally flows to the bottom and air
goes to the top. If it gets low enough, the pump will begin
sucking air and will soon loose prime. This will happen much
quicker if you're drawing off the upper tank. Of course, if the
radiator is located below the engine it will take longer for
this to happen than if it is beside the engine because the air
pocket will be inside the engine rather than in the radiator.
If you have a coolant leak in flight, you'll benefit from more
time to get on the ground rather than less.
I don't see where it makes any difference which tank you return
the coolant to, but when supplying the pump, any air will risk
loss of prime. So, it makes sense to me to draw from the bottom
and return to the top. At least that's how I understand it.
In the end its Charlie's decision.
Mark,