Ample Power Genie, Manual

Page: 1 / 8

Ample Power Genie
tm
Diesel Battery Charger
Installation and Operating Instructions
Copyright c 1989 through 2015. All Rights Reserved - Ample Power Company March 4, 2017
Introduction
The Genie, Diesel Battery Charger , is a powerful battery charging
system which uses a Kubota engine to drive one or more custom
high output alternators. The marine version is freshwater cooled
with a raw water heat exchanger. The alternator is regulated with
a Smart Alternator Regulator, or EnerMatic Controller which pro-
vides current and/or power limiting limiting. The Smart Alternator
Regulator is preset at the factory, whereas the EnerMatic Controller
can be programmed using a personal computer.
The Ample Power Genie has been in production since 1989 with
many thousands of Amp-hours produced for thousands of happy
users. The unit has been improved in many significant and minor
ways since it was first introduced and is truly unsurpassed in per-
formance.
Warnings
Over the years many mistakes have been made with unhappy re-
sults. Please read this section to avoid the mistakes others have
made.
WARNING #1
Do not operate the Genie without a belt guard!
NOTE: The Genie is not equipped with a belt guard. Never
work around the Genie when it is operating. Do not mount the
Genie such that children or adults can come into contact with
the Genie when it is running. After the Genie is installed, and
before operation, provide a belt guard, or enclure to protect all
persons from harm.
WARNING #2
Do not share an intake thru-hull with another engine . . . you will
most likely flood the Genie through the water line when the other
engine is running. This has happened more than once to people
who have ignored this warning. Under all circumstances engines
flodded with water void the warranty.
WARNING #3
Do not overfill the crankcase with oil. You may get an oily bilge
when the excess blows out of the vent tube, or the vent tube may
not be able to pass enough to prevent crankcase overpressure.
If the vent tube is fed into the air intake the engine may run away
by burning the oil coming from the crankcase.
WARNING #4
Do not use pure antifreeze in the heat exchanger. Not only is pure
antifreeze a poor carrier of heat, but it also leaks through petcocks
and gaskets. Use only a 50:50 mix of antifreeze and water.
WARNING #5
If the engine is not mounted 24 inches above the waterline, use a
siphon-break between the heat exchanger and the water injection
port into the exhaust.
WARNING #6
If any portion of the exhaust system is below the waterline, use a
waterlift muffler. Mount it at least one foot below the exhaust outlet
from the engine. Follow the instructions from the waterlift muffler
manufacturer. Note that the exhaust from the muffler should go
straight up and only then slope toward the exhaust thru-hull fitting.
WARNING #7
Do not overcool the engine. Overcooling will result in carbon build
up and loss of power. This problem may occur in cold climates.
WARNING #8
Do not adjust the current higher than what the engine can provide
without struggling. A diesel will emit black smoke when it is over-
loaded. Always adjust the currentor power limit down about 15-
25% from the black smoke point.
WARNING #9
Always let the engine warm up a little before turning on the regula-
tor. When an EnerMatic Controller is used don’t program a warm
up time less that two minutes. W
WARNING #10
Do not adjust the throttle linkage so that the throttle solenoid can-
not fully pull the plunger into the coil. The solenoid will burn out
in a few seconds if this happens.
Note: This is only applicable for
engines which us a solenoid to engage the throttle.
Fuel System
The single cylinder Genie must be fed from a gravity tank, or an
electric fuel pump. Note: Do not use a fuel pump that exceeds 10
PSI.
The two and three cylinder engines have a lift pump, but it will not
reliably lift more than a couple of feet nor through a long fuel hose.
Poor fuel delivery is a common cause of engine stalling.
A fuel return line is required. It is often possible to share an elec-
tric pump with the main engine, and almost always you can
T the
return line with that of the main engine. The return line fitting is
located at the injector.
No fuel filters are supplied with the Genie. A filter is required,
however. If you are not using the filters for the main engine to
supply fuel to the Genie, you must mount a separate fuel filter.
A separate fuel filter and water separator unit is recommended,
rather than sharing a system with another engine.
Cooling System
The Genie uses a marine heat exchanger to remove heat from the
engine. A salt water pump is supplied with the Genie. The pump
is mechanically driven on two and three cylinder engines. On the
single cylinder engine a DC operated salt water pump is used.
Output from the pump goes to the heat exchanger. Water from the
heat exchanger is fed into the exhaust to cool it permitting exhaust
hose to be used. The hose between the heat exchanger and the
exhaust must be plumbed during installation.
Note that if the unit is to be operated below the waterline, the hose
from the heat exchanger to the muffler will need to be plumbed so
that a siphon break can be mounted 2-3 feet above the waterline.
A water screen is required. The Genie pumps up to 15 gallons per
1