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Boost converter box for the EcoFlow solar input

Boost converter box for the EcoFlow solar input

Power outages here can be long, and my EcoFlow Delta Max 1600 alone isn’t enough for them. I also have a separate 12 V LiFePO4 battery, so I wanted to connect it to the EcoFlow. The only suitable input is the solar port, and it accepts 11–100 V but at most 10 A. From 12 V that’s only about 120 W, so the voltage has to be raised first.

A boost converter module does exactly that, but a bare board with screw terminals and tiny trimmers is not something you want to use every day. So I built it into a box that looks like a PC power supply: knobs for voltage and current, a meter, a breaker and XT60 ports. The box doesn’t care what is connected to it, so it works with any 10–60 V DC source.

Front: voltage and current knobs, voltmeter/ammeter

How it works

    flowchart LR
  SRC["DC source<br/>10–60 V"] --> IN["XT60 IN"] --> BOOST["Boost module"]
  BOOST --> METER["Meter<br/>V / A"] --> CB["Breaker<br/>20 A"] --> OUT["XT60 OUT"]
  OUT --> CABLE["XT60 → XT60i cable"] --> EF["EcoFlow<br/>solar input"]
  BOOST -- fan port --> FAN["120 mm fan"]
  
  • Boost module is an 1800 W CC/CV boost converter: 10–60 V in, 12–90 V out. The V knob sets the output voltage, the I knob limits the output current.
  • Meter shows the output voltage and current.
  • Breaker is a 20 A resettable circuit breaker on the output.
  • Fan is a 120 mm PC fan on the module’s own fan port. The module’s temperature controller turns it on only when the board gets hot (about 60 °C), so most of the time the box is silent.
  • XT60 IN / OUT on the back. The label shows the limits, so I don’t have to remember them.

Back: XT60 IN and OUT, 20 A breaker, label with input and output limits

Settings

I usually set it to about 20 V with the current limit at 13 A, which is about 260 W. I choose the power to cover what the EcoFlow is currently powering. Then the load runs from the external source and the EcoFlow battery stays where it is: no energy lost on charging it just to discharge it again. With more power the EcoFlow turns on its fans, and they are very loud.

The 13 A cable

The EcoFlow solar input is an XT60i connector. The small middle pin tells the EcoFlow what is connected: positive means a car socket, and the current is limited; negative means solar. With a cable that has the middle pin connected to negative, my Delta Max takes 13 A instead of 10.

I made such a cable: a regular XT60 on the box side and an XT60i on the EcoFlow side, with a wire from the middle pin to the negative contact.

Parts

PartDetails
Boost1800 W 40 A DC-DC boost converter, 10–60 V → 12–90 V
V knob3590S-2-104L, 100 kΩ 10-turn potentiometer, replaces the CV trimmer
I knob3590S-2-502L, 5 kΩ 10-turn potentiometer, replaces the CC trimmer
MeterDC 7–100 V 20 A voltmeter/ammeter
Breaker20 A resettable circuit breaker
Fan120 mm PC fan
Connectors2× XT60
EnclosureMy own 3D-printed case

Build

The module itself is stock, including the heatsink, the onboard fuses and the fan temperature controller. I only took it apart to replace the two trimmers with 10-turn potentiometers on wires, which go to the front panel.

The case is inspired by a PC power supply: the shape, perforated sides and a 120 mm fan with a grille on top.

Inside: module on its heatsink, XT60s and breaker at the top, potentiometers and meter at the bottom

Result

The EcoFlow can now use my 12 V battery, or any other 10–60 V source, through its solar input. Once the knobs are set, the box is just two XT60 cables and a meter. During long outages the external battery powers the load through the EcoFlow, and the EcoFlow stays quiet and keeps its own charge for later.

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