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From: Brent Regan <brent@regandesigns.com>
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Art writes <<My volt 1 circuit breaker off the field of the altenator 
keeps tripping when I cycle the gear.  This happens 100% of the time 
when going up and 20% going down.>>

When a wire transverses a magnetic field a voltage is generated in the 
wire. The voltage is proportional to the strength of the magnetic field, 
the velocity of the wire and the length of the wire in the field. 
Therefore, the current supplied to the alternator field controls the 
voltage output of the alternator (for a given RPM).  Given the known 
information, either the field current is exceeding 5 1/2 amps or the 
voltage  at the regulator  sense line (OVP or Crowbar)  is exceeding the 
crowbar  trip voltage. The "Crowbar"  over-voltage circuit senses if the 
buss voltage exceeded a preset limit. If it does, the regulator shorts 
the field lead to ground, causing the field breaker to trip, turning 
"off" the alternator.

All wire and connections have resistance and when a current is passed 
through a resistance it results in a voltage drop so as the current 
output of the alternator increases the voltage output of the alternator 
must also increase.

Possible causes include (in order of probability):

A high resistance connection in the high current path between the 
alternator and the battery or the battery and the loads (depending on 
where your sense line is connected).  High resistance will most likely 
be found at crimped connections, then at clamped or bolted connections 
then in the wire itself if internal strands have broken due to 
vibration. The battery also has an internal resistance that increases as 
the battery ages.

An alternator with an exceptionally low field resistance (< 2.5 ohms). 
The tested the output of the alternator, did they test the field current?

An intermittent voltage sense connection.

Faulty voltage regulator.

Carefully inspect all your high current connections for corrosion, 
looseness or broken strands. Measure the alternator field resistance at 
the alternator with the field disconnected. Inspect your regulator 
connections.

Regards
Brent Regan