You might get more luck asking the ACE team

Staszow from IF4 Lite is a lovely map - big open terrain, lots of enterable buildings and works great with ALiVE.

You can save custom variables:

http://alivemod.com/wiki/index.php/Persistence#Editor_Notes

Simply name the marker (variable name, not text field) and put that variable name in the blacklist field of the relevant module.

Are you registered on the war room with your playerid connected to game data?

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Sure you can exceed it, that's the definition of "reinforcements" vs "replacements" after all.

Mil Logistics works by calculating the difference between the current number of profiles vs the number at mission start state, so it won't request BCR for reinforcements until the mission is restarted (and assuming you have profile persistence on).

Only sync the AI Comd to the objectives module that you want him to know about. If he's not synced to the central one, he won't even know those objectives exist.

You can use one AI Comd for both factions on the same side. Assuming ANA and US are same side, you only need on Comd synced to both placement modules. Saves a bit on performance

Battle casualty replacements only. You can manually request reinforcements using the player logistics tablet

It isn't. You only need ALiVE to use the Orbat tool. Once you've create it you no longer need ALiVE to use the faction you've created. Details are in the FAQ here http://alivemod.com/wiki/index.php/Fequently_Asked_Questions