Toughtested DUAL SOLAR SWITCHBACK User Manual

The Toughtested DUAL SOLAR SWITCHBACK is a high-performance, dual-input solar charge controller designed for managing power from two separate solar panels to a single battery bank. It features Maximum Power Point Tracking (MPPT) technology, LCD display, programmable settings, overload protection, temperature compensation, and compatibility with various battery types (Gel, AGM, Flooded, Lithium). Below are key sections for safety, features, installation, setup, operation, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Solar Panels & Battery 7. Operation & Monitoring 8. Advanced Programming 9. Care & Maintenance 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Dual MPPT solar inputs, LCD status display, User buttons, Battery terminals, PV input terminals, Temperature sensor port, Communication port.

Feature	Description
Dual MPPT Inputs	Independent tracking for two solar arrays, maximizing energy harvest
LCD Display	Shows voltage, current, power, battery status, and error codes
User Buttons (MENU, UP, DOWN, ENTER)	For navigation and parameter programming
Battery Terminals (BAT+, BAT-)	For connection to 12V/24V/48V battery bank
PV Input Terminals (PV1+, PV1-, PV2+, PV2-)	For connection to two separate solar panel strings
Temperature Sensor Port	For battery temperature compensation (sensor included)
Communication Port (RS485)	For data monitoring and firmware updates (optional cable)
LED Indicators	Power, Charging, Fault status LEDs
POWER Button	Turns controller display and logic on/off (battery connection remains)
Reset Button	Factory reset (recessed, requires tool)

Installation

Unpack and inspect contents. Mount in a dry, well-ventilated location.

Connect Battery First: Ensure battery voltage matches controller rating. Connect BAT+ and BAT- terminals securely.
Connect Solar Panels: Connect PV1 and PV2 cables to respective terminals. Observe correct polarity (+/-).
Connect Temperature Sensor: Plug sensor into port and attach to battery terminal.
Secure Wiring: Ensure all connections are tight and wires are properly sized for current.

WARNING! Always connect battery before solar panels. Disconnect solar panels before disconnecting battery. High voltage present on PV terminals—risk of electric shock.

First-Time Setup

Power on controller; LCD will illuminate. Follow initial setup prompts.

Set Battery Type: Press MENU, navigate to BATTERY TYPE, select correct type (GEL, AGM, FLOODED, LITHIUM).
Set System Voltage: Navigate to SYSTEM VOLTAGE, select 12V, 24V, or 48V to match your battery bank.
Set Charging Parameters: For custom settings (e.g., Lithium), access ADVANCED menu to set bulk/float voltages.
Check PV Input: Verify on display that PV1 and PV2 voltages are detected and within limits.

CAUTION! Incorrect battery type or voltage settings can damage batteries. Refer to battery manufacturer specifications.

Specifications

Model: Toughtested DUAL SOLAR SWITCHBACK.
Max PV Input Voltage (per channel): 150VDC.
Max PV Input Power (total): 1040W @ 12V, 2080W @ 24V, 4160W @ 48V.
Charge Algorithm: MPPT with 4-stage charging (Bulk, Absorption, Float, Equalization).
Battery Voltage: 12/24/48V Auto-detect or manual.
Max Charge Current: 40A per channel, 80A total.
Display: Backlit LCD, 4-button interface.
Protections: Overload, Short Circuit, Reverse Polarity, Over-temperature, Over-voltage.
Operating Temp: -20°C to 50°C (-4°F to 122°F).
Enclosure Rating: IP65 (Dust and water jet protected).

Controls and Settings

Access menus via front panel buttons. LCD Display shows: Battery Voltage/State of Charge, PV1/PV2 Input Voltage/Current/Power, Daily Energy Harvest, Load Status, Error Messages.

Button Functions: MENU (enter/exit menu), UP/DOWN (navigate/change values), ENTER (confirm selection).

Basic Menu: Battery Type, System Voltage, Load Control Mode (Manual/Timer). Advanced Menu: Bulk/Absorption Voltage, Float Voltage, Equalization Voltage/Interval, Temperature Compensation, Load Timer Settings, Communication Address. System Info: Firmware Version, Total kWh, Runtime.

Connecting Solar Panels & Battery

Battery: Connect to BAT+ and BAT- terminals. PV: Connect Panel 1 to PV1+/PV1-, Panel 2 to PV2+/PV2-.

Ensure all power sources are OFF before making connections.
Use appropriate wire gauge (consult manual chart) to minimize voltage drop.
Install fuses/breakers on battery and PV positive lines as per local electrical codes.
After connections, power sequence: Battery ON first, then PV ON.

Tip: For best MPPT performance, ensure PV strings for each input have similar specifications and orientation.

Operation & Monitoring

Controller operates automatically once configured.

Daily Operation: MPPT algorithm continuously optimizes power from both PV inputs. Charging stage indicated on LCD.
Monitoring Data: Scroll through display pages using UP/DOWN buttons to view detailed info for each PV input and battery.
Load Control: If connected to a DC load output, set mode to Manual (ON/OFF), Timer (schedule), or Darkness (ON at dusk).
Equalization: For flooded batteries, periodic equalization can be enabled and scheduled in the menu.
Data Logging: Connect via RS485 to PC/software (optional) to record historical data and generate reports.

WARNING! Do not disconnect battery while PV panels are in sunlight and producing power. Always disconnect PV first.

Advanced Programming

Access ADVANCED menu for custom settings. Key parameters: Battery charge voltages (Bulk/Absorption/Float/Equalization), Temperature compensation coefficient, Load control timers, Low Voltage Disconnect (LVD) and Reconnect voltages, Communication settings (Baud rate, Address).

Password: Enter 0000 to unlock advanced settings (default).

Care & Maintenance

Periodically inspect terminals for corrosion and tightness. Clean exterior with dry cloth. Ensure ventilation is not blocked.

CAUTION! Disconnect all power sources (battery and PV) before performing any maintenance. Do not use liquids or compressed air for cleaning.

Regulatory Information

FCC Part 15: Class B digital device; complies with interference limits for residential use. CE marked for European compliance. Copyright © 2025 Toughtested; all trademarks are property of Toughtested Technologies, Inc. For technical support, visit www.toughtested.com/support or contact 1-800-555-0199.

Troubleshooting

Symptom	Possible Cause	Corrective Action
No display / Controller not powering on	Battery connection / voltage	Check battery connections and voltage (must be >10V for 12V system). Ensure polarity is correct.
PV Not Charging (0A shown)	PV connections / shading / settings	Check PV cable connections and polarity. Ensure panels are in sunlight. Verify battery is not fully charged.
Overload / Short Circuit Fault LED	Excessive load / wiring fault	Disconnect loads. Check for short circuits in load wiring. Reduce load below controller rating.
High Temperature Fault	Poor ventilation / ambient temp too high	Ensure controller is mounted in a cool, ventilated area. Allow to cool down. Reduce load if necessary.
Error Code on Display (e.g., E02, E05)	Internal fault / communication error	Note error code. Power cycle controller (disconnect battery & PV). If persistent, contact support.

Reset to Factory Defaults: Press and hold recessed RESET button for 10 seconds (settings will be lost).

Service & Support: 1-800-555-0199; www.toughtested.com/support