Wow.
> with the AbsorbV set at 13.8V maximum and FloatV around 13.2V it will do a bulk charge up to about 91% of the batteries capacity, then a slower charge up to about 95%, never fully charging it?
First off, the batt mfg, a BMS vendor, and **you** define where on the charge curve "100%" is. Most important is to remember from the bank's POV there is no reason to get up to that full. Just consider it a maximum not to be exceeded.
My definition of 100% is, Stop Charging when 13.9V is reached, OR keep charging at 13.8V until current acceptance falls to .02C, or 2A per 100AH, then Stop Charging.
Float of 13.2V is pretty close to Stop, since the resting voltage when full is higher.
Note the bank should never sit Full, only go up there if you've got loads that will immediately start the down cycle.
> Are these the same settings that should be programed into a solar charge controller to use with a Lifepo4 battery? (Any recommendations for a good solar charger that would allow you to program the correct settings?)
Yes, all charge sources, electricity is electricity. Nearly all decent chargers have that level of adjustability, for suggestions start a new thread.
> I checked out the owners manual for the Sterling Procharge Ultra but didn't see any specs on the starter battery. I'm a bit concerned because my starter battery / alternator may not be functioning properly (although I've been driving the van daily for 5 years without any issues). Do you know what voltage the starter battery has to be at for the Procharge Ultra to begin charging the lifepo4 battery?
Sorry, no idea what you mean, the two should not be connected at all IMO, and we're talking here about a shore charger?
> Also, could having a faulty starter battery / alternator hurt the battery charger or Lifepro4 battery in any way?
I suppose, depends on your overall system design? Each should have their own charge source, and the alt would need a lot of mods to be suitable for LFP.
> As far as usable Amp Hours, I read that a Lifepo4 battery will give you 80% discharge for around 2000 cycles, while a AGM will give you 20% discharge at around 1500 cycles.
No, down to 5% is fine, BMS should prevent further discharge or you risk your investment of thousands of dollars in LFP.
AGM, any lead, is 50%, so LFP is nearly double usable.
> an extra 500+ cycles of life, making the lifetime cost of the two types of batteries pretty similar
Lots more than that if coddled, unknown for now, and ROI decades out is very risky, especially for a beginner.
> On a Lifepo4, will setting the AbsorbV at 13.8 max and FloatV at 13.2V be enough to give you a significant amount more cycles, or are there other sorts of practices that should be considered?
The mfg docs gives all the other ways to murder them quickly. Full discharge, charging in freezing temps are a couple.
> Is the 80% discharge too much for a lifepo4, if so what do you think is best? If you look at the voltage vs SoC curves, the "shoulders" at both ends are best avoided.
> Is it recommended to take the charge down to a certain level and then recharge it (up to 95%) in the same manner every time? Or is it ok to be inconsistent... as in, taking it down to 60%, charging it to 80%, than down to 50% up to 90% etc?
No consistency required, do what is convenient.
> Also, are Lifepo4 batteries good for someone who isn't a full time van dweller. If the battery is only used for a couple weeks at a time every few months, is that sort of inconsistent use bad for the battery? Should it be disconnected during times on non use?
Yes, because they prefer to be at low SoC when not being cycled, but are scrap if allowed to fully discharge. Periodically add 5% to counteract self-discharge. Keep cool and dry but not freezing.