A real-world trial in Switzerland moved megawatt charging from theory to practice. A long-haul electric truck with an ~1 MWh battery pack went from roughly 10% to 80% state of charge in 42 minutes. The session delivered around 625 kWh, averaging close to 0.9 MW with a peak near 1.1 MW. The site used a containerized charger with a battery buffer to smooth grid demand and sustain high output.

Why it matters for operations

• Fits the driver break window: long-haul routes can plan a meaningful top-up without blowing the schedule.

• Eases grid constraints: buffer-assisted hubs can start smaller, then scale connection capacity over time.

• Signals hardware maturity: connectors, cables, and cooling systems are being validated under real loads, not just in labs.

Key Specifications for Megawatt-Class Connectors

• Continuous power, not just peak: share temperature-rise and voltage-drop data for full 30–45-minute sessions at ≥1 kA, across hot and cold conditions.

• Cooling design and service: coolant type, leak detection, pump redundancy, and whether the front end can be swapped without draining the loop.

• Ergonomics at the apron: handle weight and grip with gloves, bend radius, and options like booms or retractors to manage heavy cables safely.

• Safety and telemetry should include HVIL continuity, temperature sensors on the pins and in the coolant loop, pressure/flow monitoring, and a clear thermal derating policy.

• Environmental hardening: IP/IK targets, salt-spray and gravel-impact test results, icing behavior, and abrasion resistance when cables contact the ground.

• Interoperability roadmap: evidence of cross-vendor testing and a certification plan; ability to run CCS2 HPC and MCS side by side during transition years.

• EMC and communications: shielding and error-rate data at high current; immunity to noise in real depot environments.

• Serviceability and total cost: MTTR for common failures, availability of seal/contact kits, and warranties sized for high-utilization depots.

• Site realities: confirm cooling performance and connector durability under back-to-back sessions and longer leads common in truck bays.

Workersbee note

Start with one MCS pilot lane and run it like a real shift. Track three signals that actually decide success: bay uptime, steady power across the whole session, and connector temperature. Select hardware that can be serviced and diagnosed within minutes, and ensure drivers can plug in, reach the bay, and route the cable comfortably. Keep a CCS2 high-power lane alongside for a smoother transition. Scale only after the pilot data is solid and the maintenance plan is simple and agreed.

For a practical deep dive on power levels, ergonomics, and compliance checklists, see our in-depth guide: Megawatt Charging System (MCS) Guide for Heavy-Duty EVs — 2025