For anyone using car alternators to charge battery banks, heres how its done.
Slowly tidying the AV1 install as i catch up on other work. The important thing right now its up and running. It doesnt look as nice as the Lister, I guess ill just need to get used to it.
Looking into the rear of the alternator, all the diode block and regulator have been removed. Three heavy 20 amp cables are connected directly to the three stator coil terminations, and two lighter 5 amp wires connect direct to the brushes, 1 wire on each brush
The three stator connect to the remote diode block, there are six diodes in all. The ones i used were got from the scrap dealer from some defunct industrial equipment, an absolute overkill, these are rated at several hundred amps each. 30 amp stud mounts are sufficient to extract 80 or so amps from an alternator, as the cooling is more effective when remotely mounted like this.
The two brush wires, one connects to battery negative, the other to battery positive through a switch, this turns off the amp or so current drain when the engine is not running. To reduce the charging current , and there are good reasons to do this, a resistor is wired in series with the on/off switch mentioned above. I use a car coil ballast resistor, reducing the current from 85 amps to 50 amps. Reducing current will make the alternator last longer, will allow a smaller engine to work less, and is great for a periodic equalising charge when the banks reach 15 volts. ... assuming a 12 volt system, my setup has a switch across this resistor to give high and low charging rates.
With the regulator removed, these alternators will happily charge well above 17 volts, and maintain their full output current.
There seems to be two types of alternator, the usual one is around 55 amps, the bigger version 75 amps nominal, although both once modded will output well in excess of this for a short period.... just watch the heating in the stator windings.
Alternators will work in either rotation, BUT.... the fan is designed to suck through when running clockwise. The fan will need modding if running counter.... look for a fan with straight and not angled blades, these will then work in either direction.
A 24 volt alternator will work identically to the above, just halve the current and double the voltage, the wattage remains the same, as does the horsepower required.
By remoting the diodes, an alternator will last years rather than a few months when using it as it comes.
Its also beneficial to the engine to increase the alternator pulley diameter to spin the alternator at around 1000 to 1500 rpms, this reduces wear on belts, requires less power, and increases bearing life and belt to pulley contact.
I have found this to be the easiest and cheapest way to charge batteries with a decent amount of current and using commonly available parts.