Yep, it has been a while since I put anything up about what is going on. That is mainly because I really didn't know where it was all going
.
Bottom line is that the initial results looked like the system addition of the Wakespeed alternator regulator was going to work well, but when it got to the details of accuracy, repeatability, and stability, the Wakespeed fell quite a bit short for our application.
The system was a two alternators in parallel setup with both alternators running off the Wakespeed regulator. A shunt is used to control the amps out of the Wakespeed and end charging appropriately. Sounds simple and our old AGM setup worked fine that way, but the Charles/Amplepower regulator was not adjustable enough to handle lithium batteries.
Without going in to too much detail, here are the major issues encountered in trying to get it to run properly.
The Wakespeed uses a "sense" wire to activate it like many alternators do, but the way they have it set is that it requires a 12v signal to start. The sense wire on modern vehicles is not a 12v signal like the old points or early electronic ignition modules were, it is a 5v data level signal from the PCM. Our van is a 2007 Chevy so surely not a recent change from the 12v signal days that commonly came from the oil pressure sending unit to prove actual running. Wakespeed says to go to the key "run" position to get the 12v but that doesn't confirm engine running. Big hazard in that in that if the key is on but the engine not running, the regulator will go to full field current and burn up the regulator very quickly. Many diagnostics are run in "key on/engine off" mode so asking for problems there. The only 12v switched, and confirmed running, source I could find was the fuel pump power so I tapped into that and it worked fine. Newer vehicles with variable speed pumps might not be able to do that and neither would those that switch ground instead of power to the pump. I lucked out there I think. The real bummer is that the Wakespeed has an input connector to a stator tap which the could use to confirm actual running, but they don't use it for that which makes little sense to me.
The next major thing was that the Wakespeed just didn't like the system without the coach batteries connected. It would still see the starting battery, but it had problems controlling the voltage even though it was told to not try to cause a reading in the shunt by programming in zero amps when in float. I finally just decided to take the second alternator to being a standalone to simplify it all. The system was designed and built to be able to do that easily so it took about two hours, only.
It ran much better as a standalone, and appeared that it would all work out until I did the actual accuracy testing on the charging. The goal was to charge to a voltage and tail amp setting to terminate charging at a point under true 14.6v charged full lithium batteries to help preserve life and capacity. Since the tail amp control is a "must be under" test it was pretty much doomed to fail in a system that runs at various speeds, like a vehicle does. It would be charging away, but when I slowed down the amps would drop and it would think it was done and go to float. This is pretty much going to happen to all systems like this because they even have settings to intentionally turn down the alternator charging when at idle or low rpm to prevent alternator overheating from it trying to maintain the high charge rate. On a setting of 60 amps or lower it would often trip out at over 100 amps and leave the charging short of where we wanted to be.
I really, really didn't want to use a DC to DC charger because there really aren't any that I could find that were settable enough to be able control charging to stay in the mid SOC range accurately, plus they are very large and relatively inefficient in the higher amp version.
Finally, I remembered that the Victron battery monitors had a switched output built into them that could be used for various things so I decided to take a look at them to see if they could be made to do what I wanted to do.
As it turns out, the Victron monitors will do what I want very easily and the testing indicates they also do it very well. Using one actually even makes the system totally automatic if I want and will only come on with the engine running and SOC having dropped below 40% of our arbitrary full point which is at about 90% of full capacity. It will charge every time the van is running until it hits 90% SOC of our full setting and then shut off the regulator until the SOC is again under 40%.
The relatively obvious issue that could come up is defining the arbitrary full point and consistently being able to get to it accurately and synchronize the Victron to that point as it will drift a bit due to charge/discharge efficiency differences. We can charge to that reference point accurately with the shore power charger, which is a Magnum MS2000 running on an ARC-50 remote. We charge to 13.6v and 53 amps tail current and we are at reference point. I just do a many synchronize on the Victron and good to go. Based on what we saw on our last fall test trip with the old regulator system, the monitors are not going to drift much at all because of the high lithium charge efficiency and relatively low C rate charging. Maybe needed every 30 charges which would still be months of use continuously. We only need to charge every 5 days or so to stay within the 40-90% range. My guess is that I will only being doing the referencing when the batteries have been disconnected for a while during storage which is usually once or twice a year.
The proof or not of it all will come when we get out in the real world of use as you can't test for stuff that you don't know is going to happen
We have a thee week spring trip coming up that we probably never bother to plug in for at all, like we did our fall test trip. Exception would be if it gets horribly hot, which can happen where we are going that time of year. in the last 5 years we had 3 that were very hot and two that were nicely cool. 15 years ago it never got all that hot on the same trip.

Bottom line is that the initial results looked like the system addition of the Wakespeed alternator regulator was going to work well, but when it got to the details of accuracy, repeatability, and stability, the Wakespeed fell quite a bit short for our application.
The system was a two alternators in parallel setup with both alternators running off the Wakespeed regulator. A shunt is used to control the amps out of the Wakespeed and end charging appropriately. Sounds simple and our old AGM setup worked fine that way, but the Charles/Amplepower regulator was not adjustable enough to handle lithium batteries.
Without going in to too much detail, here are the major issues encountered in trying to get it to run properly.
The Wakespeed uses a "sense" wire to activate it like many alternators do, but the way they have it set is that it requires a 12v signal to start. The sense wire on modern vehicles is not a 12v signal like the old points or early electronic ignition modules were, it is a 5v data level signal from the PCM. Our van is a 2007 Chevy so surely not a recent change from the 12v signal days that commonly came from the oil pressure sending unit to prove actual running. Wakespeed says to go to the key "run" position to get the 12v but that doesn't confirm engine running. Big hazard in that in that if the key is on but the engine not running, the regulator will go to full field current and burn up the regulator very quickly. Many diagnostics are run in "key on/engine off" mode so asking for problems there. The only 12v switched, and confirmed running, source I could find was the fuel pump power so I tapped into that and it worked fine. Newer vehicles with variable speed pumps might not be able to do that and neither would those that switch ground instead of power to the pump. I lucked out there I think. The real bummer is that the Wakespeed has an input connector to a stator tap which the could use to confirm actual running, but they don't use it for that which makes little sense to me.
The next major thing was that the Wakespeed just didn't like the system without the coach batteries connected. It would still see the starting battery, but it had problems controlling the voltage even though it was told to not try to cause a reading in the shunt by programming in zero amps when in float. I finally just decided to take the second alternator to being a standalone to simplify it all. The system was designed and built to be able to do that easily so it took about two hours, only.
It ran much better as a standalone, and appeared that it would all work out until I did the actual accuracy testing on the charging. The goal was to charge to a voltage and tail amp setting to terminate charging at a point under true 14.6v charged full lithium batteries to help preserve life and capacity. Since the tail amp control is a "must be under" test it was pretty much doomed to fail in a system that runs at various speeds, like a vehicle does. It would be charging away, but when I slowed down the amps would drop and it would think it was done and go to float. This is pretty much going to happen to all systems like this because they even have settings to intentionally turn down the alternator charging when at idle or low rpm to prevent alternator overheating from it trying to maintain the high charge rate. On a setting of 60 amps or lower it would often trip out at over 100 amps and leave the charging short of where we wanted to be.
I really, really didn't want to use a DC to DC charger because there really aren't any that I could find that were settable enough to be able control charging to stay in the mid SOC range accurately, plus they are very large and relatively inefficient in the higher amp version.
Finally, I remembered that the Victron battery monitors had a switched output built into them that could be used for various things so I decided to take a look at them to see if they could be made to do what I wanted to do.
As it turns out, the Victron monitors will do what I want very easily and the testing indicates they also do it very well. Using one actually even makes the system totally automatic if I want and will only come on with the engine running and SOC having dropped below 40% of our arbitrary full point which is at about 90% of full capacity. It will charge every time the van is running until it hits 90% SOC of our full setting and then shut off the regulator until the SOC is again under 40%.
The relatively obvious issue that could come up is defining the arbitrary full point and consistently being able to get to it accurately and synchronize the Victron to that point as it will drift a bit due to charge/discharge efficiency differences. We can charge to that reference point accurately with the shore power charger, which is a Magnum MS2000 running on an ARC-50 remote. We charge to 13.6v and 53 amps tail current and we are at reference point. I just do a many synchronize on the Victron and good to go. Based on what we saw on our last fall test trip with the old regulator system, the monitors are not going to drift much at all because of the high lithium charge efficiency and relatively low C rate charging. Maybe needed every 30 charges which would still be months of use continuously. We only need to charge every 5 days or so to stay within the 40-90% range. My guess is that I will only being doing the referencing when the batteries have been disconnected for a while during storage which is usually once or twice a year.
The proof or not of it all will come when we get out in the real world of use as you can't test for stuff that you don't know is going to happen

We have a thee week spring trip coming up that we probably never bother to plug in for at all, like we did our fall test trip. Exception would be if it gets horribly hot, which can happen where we are going that time of year. in the last 5 years we had 3 that were very hot and two that were nicely cool. 15 years ago it never got all that hot on the same trip.