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