My first question is on your option one, “Honda 2000 Generator -> SMB installed breaker panel -> Blue sea 7622 ML-ACR Automatic Charging Relay”. What SMB installed breaker panel are you referring to? The AC Breaker panel? 12 Volt? Do you have a AC charger built in? I guess the question is are you using AC-out of the generator or the 12-volt charging port.
The Blue Sea 7622 ACR is not a charging device is just allows you to connect the two battery systems together. When the van is running it will let the alternator charge the additional capacity of your house battery system.
One could make a case to disable the 7622 when charging the house battery system. Especially if you are limited with your house charging (solar). It is possible that a bad (old) starter bat could be stealing some of your limited power.
It would be nice to install a proper battery monitor, this would give you better status on the SOC of your battery, allow you to get better measurements of your daily usage and track your solar output. You should be able to get some data from your existing solar controller.
After that come up with a plan for charging your house battery. Unfortunately, alternators are not designed to fully charge wet cell or AGM batteries. If you have been counting on that as your primary charging method, your house bank has most likely been undercharged and has lost capacity.
Solar can help with that, but that general charging algorithm takes time, once you hit the absorption stage, the charger turns into constant voltage controlled current mode. The phase takes time (default 2 hours) and sometimes we never get the battery to 100% SOC. While solar is great and can help extend your trip, it may not have enough time to fully charge your battery.
Being that AGM likes to be fully charged as soon as possible, it behooves us to have a plan in pace that can fully charge the House battery bank. While that may be impossible while out on your trip, it should be completed once you are back.
You didn’t say the size of your existing solar panel, So I will assume that it is a 100-watt panel. The SB3000i that you have can support about 400 watts of solar panel input. You will need to gather the pertinent information for Voc. Vmp, Imp and Isc information to try and match up a new panel. One option would be to run a parallel portable panel. A couple different sizes can be found at
Lensun Solar.
It is tough to say what your expected power usage will be with the fridge. The answer will be drastically different based on temperature. I can see a 2X power increase on very hot days.
Solar output will also very with location and time of year. The good news is that increased solar output generally comes on the days of 2X fridge power usage. You can increase solar output if you allow the ability to tilt your panels. I know the reality is that I wouldn’t want to climb up on the van to tilt the panels. The good news is that would not be a big issue with some portable panels deployed.
Depending on the age of your house battery bank, and how well maintained would determine how much capacity it still has. Very possible it is more like a 175 Ahr bank now or less.