DeWalt TOUGHSYSTEM 2.0 20V MAX Dual Port Charger

Why I added this box to my ToughSystem stack

I’ve been trying to tame a growing pile of 20V MAX and FLEXVOLT batteries without dedicating a table to a tangle of chargers. The ToughSystem dual‑port charger promised two things I care about: a proper storage home for a dozen packs and a sealed, jobsite‑ready charger I can plug in anywhere. After several weeks of daily use—on a cart in the shop, stacked on a rolling ToughSystem base, and tossed in the truck—this has become my default battery hub.

Setup and integration

Out of the box, it clicks into a ToughSystem 2.0 stack with the auto‑connect side latches and feels as solid as any of DeWalt’s 2.0 boxes. Loaded, the weight creeps up quickly (empty it’s about 9 lb), but the handle and latches feel trustworthy with a dozen packs inside. The footprint is roughly 9 × 15 × 14 in, which nests fine on a DS400 or rolling base without overhang.

Do note that there are regional versions: mine is a 120V unit. I’ve also seen listings pointing to 230V plugs and a CE mark. If you travel or buy internationally, double‑check voltage and plug type before you commit.

Charging performance and speed

This is a dual‑port simultaneous charger. Both bays work at the same time rather than sequentially, which matters when you’re rotating packs through the day. DeWalt rates the maximum charge current at 4A with a typical 5.0Ah pack going from flat to full in the 75–80 minute range. That matches what I saw with DCB205s and PowerStack packs: it’s not a “rapid” charger, but it’s consistent and gentle on batteries. FLEXVOLT 6.0/9.0Ah packs also charge without drama, though obviously they take longer.

There’s active cooling built in. The internal fan kicks on under load or in warm conditions, and the box never got more than mildly warm to the touch. Fan noise is a soft whirr—audible in a quiet shop, lost on a jobsite. Importantly, the fan and the IP55 sealing play nicely together; nothing inside has collected dust despite plenty of drywall and sawdust floating around.

LED indicators are clear and useful. Each bay has an interior status LED, and there’s an exterior repeat so you can see charge states with the lid closed or when the box is stacked. I like being able to glance at the stack and decide whether to grab a pack or keep working off the cord for a few more minutes.

Storage and organization

The interior is a big selling point: it holds up to 12 batteries in the main compartment, plus two more on the charging rails when you’re not charging. I’ve carried a mixed load—2.0Ah compacts, 5.0Ah PowerStacks, and a few FLEXVOLT bricks—without issue. If you carry only big FLEXVOLT packs, capacity drops, but it’s still a tidy footprint compared to a separate box plus loose chargers.

One thing to know: the compartment is open; there aren’t molded dividers for each battery bay. That’s fine for short hops, but on longer drives, batteries can shuffle. A simple fix is to add foam, printed dividers, or a small organizer insert to snug everything up. With a little planning, I’ve got dedicated “lanes” that keep the packs upright and silent.

Two habits I’ve adopted:
- I don’t store batteries clipped on the charge rails when the box is unplugged. It’s just good practice to keep storage and charging separate.
- I label the top of each pack with capacity and date. The box makes it easy to keep a rotation going and retire packs before they become a problem.

USB and power convenience

There’s an internal USB‑A port and an external USB‑C port for personal devices. Handy, but temper expectations: they’re best for topping off a phone, earbuds, or a headlamp—not running a laptop. In my testing, the USB ports only output power when the charger is connected to AC; there’s no internal battery or “power station” mode that draws from the tool packs. If you want off‑grid USB, plan on a separate power supply.

Durability and weather protection

ToughSystem 2.0 boxes are proven, and this one keeps to form. The gaskets and latches deliver an IP55 rating, which has been enough to shrug off rain, washdowns, and jobsite dust. It’s not a dunkable Pelican case, but for real‑world use—exposed loading docks, sawdust, and the occasional coffee mishap—it’s more than adequate. The hinges and lid lock inspire confidence; the lid stays put when you’re swapping packs mid‑charge, which makes one‑handed battery changes far easier than with a floppy lid.

Day‑to‑day usability

A few small details stand out:
- The exterior status LEDs are bright enough to read from across a room but not obnoxious in low light.
- The lid lock is genuinely useful: pop it open, click in a depleted pack, grab a fresh one, and go.
- Cord management could be better. I would have loved a dedicated wrap or compartment. I ended up adding a short Velcro strap to keep the cord tidy when I’m moving between sites.
- Stacked stability is excellent, even when this box is sandwiched between heavier drawers and organizers. The auto‑connect latches are the unsung hero of ToughSystem 2.0.

The only “gotcha” is weight. A dozen packs plus the box can be a 25–30 lb lift. It’s a fair trade for consolidated storage, but plan your stack so this isn’t the highest box you’re grabbing off the cart.

What could be better

• Faster charging option: At 4A per bay, this prioritizes battery longevity over speed. I’m fine with that for solo or small‑crew work. If you run a large crew or high‑draw tools all day, you may still want a rapid charger or a second unit to keep up.
• Interior organization: A configurable insert or divider kit from DeWalt would be welcome. The open well is versatile, but shipping with modular dividers would elevate the experience.
• USB power: The external USB‑C is convenient, but higher‑wattage PD would be more useful for tablets or field laptops.
• Clearer regional spec: Listings that show 120V voltage and a 230V plug are confusing. DeWalt does sell regional variants, but the product page should make your exact version obvious.

Who this is for

• Trades and shops already invested in ToughSystem 2.0 who want a single, sealed home for their batteries and a dual charger that can live in the stack.
• Mobile technicians who need to roll into a site, plug in one cord, and get two bays charging while keeping the rest of the packs protected.
• Anyone prioritizing battery health and organization over maximum charge speed.

Who might look elsewhere:
- Crews burning through dozens of packs per day who need 8A rapid charging or more ports. You’ll either supplement with faster stand‑alone chargers or run two of these boxes.
- Users who need off‑grid charging. This is an AC‑only charger; it’s not an inverter or power station.

The bottom line

The ToughSystem dual‑port charger solves a very practical problem: it consolidates a pile of batteries and chargers into a rugged, weather‑resistant box that integrates cleanly with the rest of your stack. Charging performance is steady and predictable, the cooling system works, and the interior/exterior LED indicators remove guesswork. As a storage solution, it’s roomy and adaptable enough for a mixed fleet of 20V MAX and FLEXVOLT packs, though it benefits from a bit of DIY organization.

It isn’t the fastest charger on the market, and it won’t power your devices off the grid. But for most single‑user and small‑crew workflows, the balance of protection, organization, and simultaneous dual‑bay charging hits the sweet spot.

Recommendation: I recommend it to anyone already invested in DeWalt’s ToughSystem 2.0 who wants to centralize battery storage and add a reliable dual‑bay charger without giving up durability or stackability. If you need rapid charging or off‑grid power, pair this with a faster stand‑alone charger or a separate power supply; otherwise, this box will tidy your battery life and make your day-to-day a lot simpler.