Why Megawatt Charging?

As the electrification of heavy-duty transport accelerates, the demand on charging infrastructure is increasing exponentially. While the Combined Charging System (CCS) supports charging power up to 500 kW, this is insufficient for heavy-duty vehicles with battery capacities ranging from 500 to 1000 kWh. This is where the Megawatt Charging System (MCS) comes into play, a new charging standard that enables charging power of up to 3.75 MW (3000 A at 1250 V DC).

Technical Specifications of MCS

• Maximum charging power: 3.75 MW
• Voltage: Up to 1250 V DC
• Current: Up to 3000 A
• Communication: Automotive Ethernet (IEEE 10Base-T1S), replacing Powerline Communication (PLC) used with CCS
• Connector design: Liquid-cooled, with automated locking and optional robotic support

These specifications make it possible to charge a 1000-kWh battery in under 30 minutes, an essential factor for the economic operation of electric trucks in long-haul transport or other heavy-duty vehicles.

Industries and Application Areas

The introduction of the Megawatt Charging System (MCS) opens new possibilities for electrifying vehicles and machines with particularly high energy demands. Industries that rely on large battery capacities, short charging times, and high availability stand to benefit the most. Key application areas include:

• Long-haul transport and logistics: Charging times under 45 minutes enable break-compliant charging in accordance with EU driver regulations.
• Mining vehicles: Electrification of large haul trucks and loaders operating in remote or underground environments, requiring robust and fast charging solutions.
• Construction and agricultural machinery: Electrification of heavy off-highway vehicles.
• Maritime applications: Electric ferries and harbor tugs requiring high charging power.
• Airport operations: Ground support equipment such as pushbacks and baggage tractors.
• Public transport and bus depots: Fast depot charging overnight or at terminal stops.

Technological Challenges

The implementation of the Megawatt Charging System (MCS) introduces a range of complex technical challenges that go far beyond current e-mobility standards. One of the most critical hurdles is thermal management. At current levels of up to 3000 amps, significant heat losses occur, which not only reduce efficiency but also pose safety risks. To reliably dissipate this heat, MCS relies on an actively cooled cable and connector system with liquid cooling, ensuring stable thermal performance even under continuous load.

Another key aspect is electrical safety. With charging voltages reaching up to 1250 volts, the requirements for insulation, overvoltage protection, and arc detection increase significantly. The MCS specification, therefore, includes multi-layered safety mechanisms at both the hardware and protocol levels. These include galvanic isolation, automated locking systems, and continuous monitoring of electrical parameters throughout the charging process.

Communication between the vehicle and the charging infrastructure also undergoes a fundamental shift with MCS. Instead of the previously used Powerline Communication (PLC), an automotive Ethernet-based communication technology (IEEE 10Base-T1S) is implemented. This change is necessary to ensure electromagnetic compatibility at high power levels while enabling robust, low-latency data transmission, especially for charging control commands and authentication processes.

Finally, the physical handling of the system presents its own challenges. Due to the size and weight of the MCS connector and cable, the use of robotic charging systems is being considered in many applications. These systems aim to improve ergonomics and enable automated, standardized charging infrastructure for fleets and logistics hubs.

Infrastructure and Grid Requirements

Implementing megawatt charging systems places significant demands not only on vehicle technology but also on charging infrastructure and energy supply. Due to the extremely high-power levels, up to 3.75 megawatts per charging point, a direct connection to the medium-voltage grid is typically essential. This means that MCS stations cannot be operated via conventional low-voltage connections like standard fast chargers. Instead, they require dedicated transformers and switchgear to deliver the necessary power.

A central issue in this context is load management. To avoid grid overloads while maintaining economic viability, MCS sites must be equipped with intelligent energy management systems. These systems coordinate charging schedules, prioritize vehicles based on operational needs, and can integrate local energy sources such as photovoltaic systems or stationary battery storage. Especially in logistics hubs or highway corridors where multiple vehicles may charge simultaneously, dynamic load balancing is critical.

Scalability is another key consideration. The infrastructure must be designed to grow with increasing demand, both in terms of physical layout and grid capacity. This requires close collaboration between charging infrastructure providers, utility companies, and local authorities, particularly when it comes to permitting and expanding medium-voltage connections.

Standardization also plays a decisive role. Only if MCS charging points are interoperable across manufacturers and can be seamlessly integrated into existing backend systems, a widespread rollout will be successful. The CharIN initiative is therefore working intensively on the global harmonization of MCS specifications to ensure interoperability and investment security.

What comes next: MCS as a Strategic Enabler of Transport Decarbonization

The Megawatt Charging System is on the verge of industrial deployment and is expected to play a central role in transforming the transport sector over the coming years. Initial pilot projects involving MCS-capable vehicles and infrastructure are already underway in Europe and North America. From 2025 onward, broader market adoption is anticipated, particularly in long-haul transport, where charging time and range are critical economic factors.

In the long run, MCS will extend beyond highway corridors and logistics centers. It will also be implemented in multimodal transport hubs like ports, airports, and industrial areas. In these settings, MCS can act as a technological link between different modes of transportation, supporting seamless electrification, from trucks to ships to automated ground vehicles.

Another driver of MCS adoption is the increasing automation of fleet operations. Combined with autonomous vehicles and robotic charging systems, fully automated charging processes could emerge, operating around the clock and offering a major advantage for logistics companies with high throughput and tight schedules.

From a regulatory perspective, the direction is also clear: the EU and other regions are tightening CO₂ fleet limits and promoting zero-emission zones, further accelerating demand for high-performance charging infrastructure. Incentive programs and regulatory support are expected to boost the rollout of MCS sites.

Technologically, the system is designed to be scalable and future-proof. The combination of high charging power, standardized interfaces, and digital communication makes MCS a platform technology, well-suited for future applications such as bidirectional charging (vehicle-to-grid) or grid-supportive load shifting.

In summary, MCS is much more than just a new connector, it is a crucial part of the energy transition in the transportation sector. Those who invest in this technology today are laying the groundwork for an emission-free, efficient, and connected heavy-duty transport system of the future.

How Keysight Supports the Transition to Megawatt Charging

In this dynamic environment, Keysight supports OEMs, charging infrastructure providers, and component manufacturers in navigating the technical challenges of megawatt charging. With decades of experience in high-power electronics, automotive testing, and energy systems, Keysight offers comprehensive test and validation solutions focused on performance, safety, and interoperability across the entire MCS ecosystem.

By aligning with standards such as ISO 15118-20 and actively contributing to the development of the MCS specification, Keysight test solutions ensure that new MCS solutions meet both current and future requirements. Whether you’re developing next-generation charging systems or validating individual components, Keysight provides the tools and expertise to accelerate development cycles and reduce time-to-market.

Keysight’s solution portfolio includes:

• High-power test systems for EVSE and EV interface components
• Conformance and interoperability testing for ISO 15118 and MCS protocols
• Power quality and thermal behavior analysis
• Advisory services for system architecture and compliance

With this combination of technology, experience, and industry insight, Keysight is a trusted partner in building a safe, scalable, and future-ready charging infrastructure – designed to meet the demands of next-generation electric heavy-duty transport.

Learn more about the Megawatt Charging Test Solution at: www.keysight.com/megawatt-charging

Why Megawatt Charging?

As the electrification of heavy-duty transport accelerates, the demand on charging infrastructure is increasing exponentially. While the Combined Charging System (CCS) supports charging power up to 500 kW, this is insufficient for heavy-duty vehicles with battery capacities ranging from 500 to 1000 kWh. This is where the Megawatt Charging System (MCS) comes into play, a new charging standard that enables charging power of up to 3.75 MW (3000 A at 1250 V DC).

Technical Specifications of MCS

• Maximum charging power: 3.75 MW
• Voltage: Up to 1250 V DC
• Current: Up to 3000 A
• Communication: Automotive Ethernet (IEEE 10Base-T1S), replacing Powerline Communication (PLC) used with CCS
• Connector design: Liquid-cooled, with automated locking and optional robotic support

These specifications make it possible to charge a 1000-kWh battery in under 30 minutes, an essential factor for the economic operation of electric trucks in long-haul transport or other heavy-duty vehicles.

Industries and Application Areas

The introduction of the Megawatt Charging System (MCS) opens new possibilities for electrifying vehicles and machines with particularly high energy demands. Industries that rely on large battery capacities, short charging times, and high availability stand to benefit the most. Key application areas include:

• Long-haul transport and logistics: Charging times under 45 minutes enable break-compliant charging in accordance with EU driver regulations.
• Mining vehicles: Electrification of large haul trucks and loaders operating in remote or underground environments, requiring robust and fast charging solutions.
• Construction and agricultural machinery: Electrification of heavy off-highway vehicles.
• Maritime applications: Electric ferries and harbor tugs requiring high charging power.
• Airport operations: Ground support equipment such as pushbacks and baggage tractors.
• Public transport and bus depots: Fast depot charging overnight or at terminal stops.

Technological Challenges

The implementation of the Megawatt Charging System (MCS) introduces a range of complex technical challenges that go far beyond current e-mobility standards. One of the most critical hurdles is thermal management. At current levels of up to 3000 amps, significant heat losses occur, which not only reduce efficiency but also pose safety risks. To reliably dissipate this heat, MCS relies on an actively cooled cable and connector system with liquid cooling, ensuring stable thermal performance even under continuous load.

Another key aspect is electrical safety. With charging voltages reaching up to 1250 volts, the requirements for insulation, overvoltage protection, and arc detection increase significantly. The MCS specification, therefore, includes multi-layered safety mechanisms at both the hardware and protocol levels. These include galvanic isolation, automated locking systems, and continuous monitoring of electrical parameters throughout the charging process.

Communication between the vehicle and the charging infrastructure also undergoes a fundamental shift with MCS. Instead of the previously used Powerline Communication (PLC), an automotive Ethernet-based communication technology (IEEE 10Base-T1S) is implemented. This change is necessary to ensure electromagnetic compatibility at high power levels while enabling robust, low-latency data transmission, especially for charging control commands and authentication processes.

Finally, the physical handling of the system presents its own challenges. Due to the size and weight of the MCS connector and cable, the use of robotic charging systems is being considered in many applications. These systems aim to improve ergonomics and enable automated, standardized charging infrastructure for fleets and logistics hubs.

Infrastructure and Grid Requirements

Implementing megawatt charging systems places significant demands not only on vehicle technology but also on charging infrastructure and energy supply. Due to the extremely high-power levels, up to 3.75 megawatts per charging point, a direct connection to the medium-voltage grid is typically essential. This means that MCS stations cannot be operated via conventional low-voltage connections like standard fast chargers. Instead, they require dedicated transformers and switchgear to deliver the necessary power.

A central issue in this context is load management. To avoid grid overloads while maintaining economic viability, MCS sites must be equipped with intelligent energy management systems. These systems coordinate charging schedules, prioritize vehicles based on operational needs, and can integrate local energy sources such as photovoltaic systems or stationary battery storage. Especially in logistics hubs or highway corridors where multiple vehicles may charge simultaneously, dynamic load balancing is critical.

Scalability is another key consideration. The infrastructure must be designed to grow with increasing demand, both in terms of physical layout and grid capacity. This requires close collaboration between charging infrastructure providers, utility companies, and local authorities, particularly when it comes to permitting and expanding medium-voltage connections.

Standardization also plays a decisive role. Only if MCS charging points are interoperable across manufacturers and can be seamlessly integrated into existing backend systems, a widespread rollout will be successful. The CharIN initiative is therefore working intensively on the global harmonization of MCS specifications to ensure interoperability and investment security.

What comes next: MCS as a Strategic Enabler of Transport Decarbonization

The Megawatt Charging System is on the verge of industrial deployment and is expected to play a central role in transforming the transport sector over the coming years. Initial pilot projects involving MCS-capable vehicles and infrastructure are already underway in Europe and North America. From 2025 onward, broader market adoption is anticipated, particularly in long-haul transport, where charging time and range are critical economic factors.

In the long run, MCS will extend beyond highway corridors and logistics centers. It will also be implemented in multimodal transport hubs like ports, airports, and industrial areas. In these settings, MCS can act as a technological link between different modes of transportation, supporting seamless electrification, from trucks to ships to automated ground vehicles.

Another driver of MCS adoption is the increasing automation of fleet operations. Combined with autonomous vehicles and robotic charging systems, fully automated charging processes could emerge, operating around the clock and offering a major advantage for logistics companies with high throughput and tight schedules.

From a regulatory perspective, the direction is also clear: the EU and other regions are tightening CO₂ fleet limits and promoting zero-emission zones, further accelerating demand for high-performance charging infrastructure. Incentive programs and regulatory support are expected to boost the rollout of MCS sites.

Technologically, the system is designed to be scalable and future-proof. The combination of high charging power, standardized interfaces, and digital communication makes MCS a platform technology, well-suited for future applications such as bidirectional charging (vehicle-to-grid) or grid-supportive load shifting.

In summary, MCS is much more than just a new connector, it is a crucial part of the energy transition in the transportation sector. Those who invest in this technology today are laying the groundwork for an emission-free, efficient, and connected heavy-duty transport system of the future.

How Keysight Supports the Transition to Megawatt Charging

In this dynamic environment, Keysight supports OEMs, charging infrastructure providers, and component manufacturers in navigating the technical challenges of megawatt charging. With decades of experience in high-power electronics, automotive testing, and energy systems, Keysight offers comprehensive test and validation solutions focused on performance, safety, and interoperability across the entire MCS ecosystem.

By aligning with standards such as ISO 15118-20 and actively contributing to the development of the MCS specification, Keysight test solutions ensure that new MCS solutions meet both current and future requirements. Whether you’re developing next-generation charging systems or validating individual components, Keysight provides the tools and expertise to accelerate development cycles and reduce time-to-market.

Keysight’s solution portfolio includes:

• High-power test systems for EVSE and EV interface components
• Conformance and interoperability testing for ISO 15118 and MCS protocols
• Power quality and thermal behavior analysis
• Advisory services for system architecture and compliance

With this combination of technology, experience, and industry insight, Keysight is a trusted partner in building a safe, scalable, and future-ready charging infrastructure – designed to meet the demands of next-generation electric heavy-duty transport.

Learn more about the Megawatt Charging Test Solution at: www.keysight.com/megawatt-charging