Megawatt-level ultra-fast charging has already reached the highways. Huawei, SF Express, and XCMG completed a 1,046-kilometer interprovincial trunk-route test using megawatt-level ultra-fast charging, while Shandong Province launched construction of its “Four Vertical and Two Horizontal” green energy replenishment corridors for electric heavy-duty trucks. Meanwhile, a growing number of operators are asking the same question: How should high-power DC charging equipment be selected? Between 400kW, 600kW, and 960kW, does higher power necessarily mean better performance?

The answer is clearly no. Charging power is not a matter of being “more advanced when larger,” but rather “more valuable when properly matched.” Selecting the wrong power range may result in idle equipment and low utilization at best, or extended payback periods and reduced overall station efficiency at worst. Combining the latest industry developments with practical experience from EAX’s Energy Flash Series charging equipment, this article presents an actionable selection method covering the complete 400kW-960kW power range.

I. The Rapid Rise of Charging Power: Technological Evolution from 120kW to Megawatt-Level Ultra-Fast Charging

High-power charging did not emerge overnight. Its development path is clearly visible:

1.1 Huawei’s Megawatt-Level Ultra-Fast Charging Test: Verification over a 1,046-Kilometer Interprovincial Trunk Route

Since 2026, the most significant event in the high-power charging sector has been the interprovincial trunk-route test of megawatt-level ultra-fast charging jointly conducted by Huawei, SF Express, and XCMG. A single vehicle completed a 1,046-kilometer long-distance journey, verifying the feasibility of megawatt-level ultra-fast charging in trunk logistics. The test delivered two important signals. First, technology is overcoming the energy replenishment bottleneck for long-distance electric heavy-duty truck transportation. Second, megawatt-level charging is no longer merely a laboratory concept; it has entered the real-world operational verification stage. Once trunk logistics begins a large-scale transition toward electrification, the charging power configuration of stations along these routes must be upgraded accordingly, directly driving demand for high-power DC charging equipment above 400kW.

1.2 Challenges Posed by High-Power Charging to Grid Capacity and Cooling Systems

Greater power creates greater challenges. Charging equipment above 400kW imposes two major constraints on charging stations. The first is grid capacity. The instantaneous load of a single 400kW charging gun places strict requirements on transformer capacity and cable specifications. Stations unable to expand grid capacity must reduce peak demand through flexible power allocation, energy storage buffering, and other measures. The second is the cooling system. Heat generated by high-power modules increases approximately in proportion to power output, making liquid cooling and intelligent temperature control standard capabilities for equipment above 600kW. These two factors directly demonstrate the value of split-type flexible charging stacks: they centrally manage a shared power pool and allocate output according to demand, fundamentally reducing the engineering pressure created by high power at individual charging points.

1.3 Product Compliance Requirements under Parallel Chinese and European Standards

Operators serving both domestic and export markets face another practical issue: the parallel use of Chinese standards (GB/T) and European standards such as CCS2 and HPC. Whether one piece of equipment can satisfy both sets of standards directly determines whether it can enter different markets. During equipment selection, priority should be given to devices compatible with both standards and supporting multiple charging outputs, leaving room for future market expansion.

II. Charging Equipment Power Levels and Application Matching Matrix

Matching the power range to the application scenario is the first step in selecting high-power charging equipment. The following table shows the relationship between current mainstream power levels and application scenarios:

Core conclusion: Selecting a power range should not be based on guesswork. It is jointly determined by four variables: vehicle type, operating shifts, site power conditions, and expected traffic volume.

· 120-360kW represents the “core foundation” for urban buses, light-duty trucks, and passenger vehicles, offering mature technology, stable performance, and controllable costs;

· 400-480kW is the primary power range for heavy-duty truck/mining truck applications and directly determines energy replenishment efficiency for trunk transportation;

· 600-960kW is suitable for medium and large charging stations. Its core value lies in “flexible power allocation”—the power pool is dispatched according to demand, preventing idle modules and maximizing equipment utilization;

· 320kW×2 DCDC parallel dual-gun output is intended for specialized applications, using two charging guns simultaneously to meet extreme power requirements.

Define the scenario first, determine the power level second, and select the equipment configuration last—this is the fundamental sequence for selecting high-power charging equipment.

III. Complete Analysis of EAX Energy Flash Series Charging Equipment

After determining the application scenario and power range, the next step is selecting the equipment configuration. As a mobile energy system solution provider, EAX Technology Co., Ltd. (Suzhou) offers the Energy Flash Series in both integrated and split-type configurations, corresponding precisely to the two primary branches of the power matrix described above.

3.1 Integrated DC Charging Equipment: Chinese-Standard 400kW / European-Standard 120-360kW

An integrated charging unit combines the power modules, control unit, and charging gun in one enclosure, providing convenient installation and flexible deployment. The Energy Flash Series integrated DC charging equipment includes a Chinese-standard 400kW model and European-standard 120-360kW models. It is suitable for urban bus stations, light-duty truck logistics parks, public fast-charging stations for passenger vehicles, and other applications sensitive to deployment speed and space utilization. European-standard models support interfaces such as CCS2, providing compliant options for export and foreign-invested customers.

3.2 Split-Type Flexible Charging Stack: Flexible Power Allocation across the Complete 600kW/720kW/960kW Range

For heavy-duty trucks, mining trucks, and medium to large charging stations, the Energy Flash Series split-type flexible charging stack is available in 600kW, 720kW, and 960kW configurations. Its core feature is flexible shared-power allocation technology. The charging stack centrally manages all power modules and dynamically distributes power according to each vehicle’s actual requirements. Multiple charging guns can operate simultaneously, avoiding the “idle power module” problem commonly found in conventional charging stations. Using the same series’ 480kW charging hub as a reference, peak efficiency exceeds 95%, the full-load power factor reaches 0.99, and multiple interfaces such as CCS2 and HPC are supported. The system can also be expanded in parallel to 960kW—allowing operators to configure power according to current requirements and subsequently upgrade through parallel expansion, thereby protecting their initial investment.

3.3 Three Core Advantages: Safety and Reliability, Modular Design, and Environmental Adaptability

· Safety and reliability: High protection level design, such as IP54 and IK10, accommodates harsh outdoor environments; full-chain fault monitoring and alarms reduce operating risks;

· Modular design: Power modules support plug-in maintenance, allowing faulty modules to be replaced immediately and reducing downtime; on-demand expansion enables power upgrades without replacing the complete unit;

· Environmental adaptability: Stable operation across a wide temperature range of -30℃~50℃ accommodates the severe cold of northern regions and the high temperature and humidity of southern regions, ensuring all-weather operation.

EAX holds more than 100 valid patents, and R&D personnel account for over 40% of its workforce. Its product portfolio covers three categories: mobile power supplies, energy replenishment equipment, and digital energy management platforms. With complete delivery capabilities covering equipment production, installation and commissioning, and operational training, EAX provides customers with system-level support combining “equipment + services.”

IV. Key Parameter Checklist for Charging Station Equipment Selection

In addition to power and equipment configuration, a group of technical parameters determines whether the equipment can genuinely meet the requirements of a charging station. The following items should be checked individually before procurement:

4.1 Output Voltage Range (Compatible with 800-1000V High-Voltage Platforms)

New-generation heavy-duty trucks and mining trucks generally use 800V and higher-voltage platforms. The output voltage range of the charging equipment must cover 800-1000V to provide full-power output to vehicles using high-voltage platforms. If the equipment’s maximum output voltage is insufficient, the actual charging power will be significantly reduced—the root cause of “rated at 400kW but unable to reach full power” is often a voltage mismatch.

4.2 Charging Efficiency and Power Factor

Charging efficiency directly determines electricity losses. Every one-percentage-point increase in efficiency creates a considerable annual cost difference at stations with high utilization. The power factor affects grid-side assessments and electricity billing, while equipment with a full-load power factor of 0.99 can significantly reduce reactive power losses. It is recommended that “peak efficiency ≥95% and full-load power factor ≥0.99” be used as the minimum qualification threshold for high-power equipment.

4.3 Protection Rating and Operating Temperature

Equipment at outdoor charging stations must withstand wind, rain, dust, high temperatures, and severe cold. Protection ratings such as IP54/IK10 and operating temperature ranges such as -30℃~50℃ are critical indicators of equipment reliability. Stations in southern coastal regions should prioritize moisture and corrosion resistance, while northern stations should prioritize low-temperature startup capability.

4.4 Intelligent Dispatching and OTA Upgrade Capabilities

A high-power charging station is not simply a device that “starts charging when plugged in,” but an energy node requiring intelligent dispatching. Whether the equipment supports dynamic power allocation among multiple charging guns, remote monitoring and fault alarms, and OTA remote upgrades determines whether it can continue evolving and whether operation and maintenance costs can be reduced.

Pre-Procurement Checklist:

· What is the vehicle’s maximum-voltage platform? Does the equipment’s output voltage range cover it?

· What is the maximum power required by one vehicle? Can a single charging gun satisfy it?

· What is the maximum number of vehicles charging simultaneously at the station? How many charging guns are required?

· Do the transformer capacity and power supply conditions permit full-load operation?

· What is the station’s climate and operating environment? Do the protection rating and operating temperature range match it?

· Is support required for European-standard/CCS2 or other export interfaces?

· What are the capabilities for after-sales response, spare-parts supply, and remote operation and maintenance?

V. Charging Station Return on Investment and Operation and Maintenance Considerations

Equipment selection must ultimately be reflected in the financial calculations. The profitability model of a high-power charging station can be summarized by two core variables:

5.1 Analysis of Equipment Costs as a Proportion of Total Charging Station Investment

Within the total investment in a high-power charging station, charging equipment—including power modules, charging units, and supporting power distribution equipment—is a primary cost component. The higher the proportion of equipment costs, the smaller the margin for selection errors—choosing the wrong power range or configuration means tying up substantial capital in unsuitable equipment. This is why “define the scenario first and select the equipment second” is so important: equipment investment should serve the established operating scenario, not the other way around.

5.2 Utilization and Electricity Price Differences Determine the Profitability Model

Charging station profitability depends on two core variables. The first is equipment utilization—an idle power module represents idle capital, which is precisely where flexible power allocation creates value. The second is the electricity price difference—the peak-valley electricity price spread and per-kWh service fee determine the gross profit of each charging unit. High-power equipment demonstrates its high-turnover advantage only at highly utilized stations. Blindly installing high-power equipment in low-traffic scenarios instead reduces returns.

5.3 Remote Monitoring and Preventive Maintenance Strategies

Operation and maintenance costs represent a major hidden expense. Equipment with remote monitoring, fault warning, and OTA upgrade capabilities can prevent many failures before they occur. Combined with a modular design enabling rapid replacement and repair, these capabilities significantly reduce station maintenance labor and downtime losses. During equipment selection, “maintenance-friendly equipment design” should be considered as important as the procurement price.

VI. EAX Energy Flash Series: Scope of Equipment Delivery Services

In the new energy replenishment sector, EAX focuses on equipment sales, production, installation and commissioning, and operational training. It provides operators and end customers with equipment options including Energy Flash Series integrated DC charging units and split-type flexible charging stacks, supporting the complete process of equipment selection, production and delivery, installation and commissioning, and operational training.

It should be noted that civil engineering, grid capacity expansion, power supply infrastructure construction, and charging station operation must be separately coordinated according to the project’s specific conditions and are not included in the equipment delivery scope. When selecting an equipment partner, customers should focus on its production capacity, delivery cycle, commissioning capability, and training system—whether equipment performs well depends equally on manufacturing quality and post-delivery service.

FAQ

Q1: How should I choose between 400kW and 960kW charging equipment?

Start with the application scenario. A 400kW unit is suitable for high-power charging at individual points, including short-haul heavy-duty truck operations and trunk-route energy replenishment. A 600-960kW split-type charging stack is suitable for medium and large charging stations with multiple parking spaces and mixed vehicle types, improving overall utilization through flexible power allocation. If future expansion is expected, prioritize equipment that supports parallel capacity expansion.

Q2: Why can equipment rated at 400kW not reach its full charging power?

The most common causes are a mismatch between the output voltage and the vehicle’s voltage platform or an unsuitable power allocation strategy within the charging stack. During selection, verify that the equipment’s output voltage range covers 800-1000V high-voltage platforms and confirm its flexible power allocation capability.

Q3: What is the difference between European-standard and Chinese-standard DC charging equipment?

The interface protocols and communication standards differ. Export applications and foreign-invested customers require equipment supporting European-standard interfaces such as CCS2 and HPC, while domestic operations primarily use the Chinese GB/T standard. Equipment compatible with both standards can serve both markets.

Q4: What power supply conditions are required for high-power charging equipment?

Equipment above 400kW places substantial requirements on transformer capacity and cable specifications. Stations unable to expand capacity can consider shared power-pool allocation through split-type charging stacks or use energy storage buffering to reduce peak loads. However, power supply infrastructure construction must be separately coordinated by the customer.

Q5: What services does EAX provide after equipment delivery?

EAX provides equipment sales, production, installation and commissioning, and operational training services. These services cover the entire process from equipment selection to commissioning and help customer teams operate equipment correctly, identify faults, and perform routine maintenance.

Conclusion

From 120kW to megawatt-level ultra-fast charging, the selection logic for high-power DC charging equipment remains consistent—application scenarios determine power, power determines equipment configuration, parameters determine technical details, and service determines returns. As heavy-duty truck electrification accelerates and energy replenishment corridors become interconnected, selecting the right equipment is more important than selecting the most expensive equipment. Which charging station power range are you considering? You are welcome to evaluate it item by item using the checklist in this article or discuss an equipment selection solution with the EAX team.

(The industry developments discussed in this article refer to publicly available information including the interprovincial megawatt-level ultra-fast charging test conducted by Huawei, SF Express, and XCMG, as well as the construction of Shandong Province’s “Four Vertical and Two Horizontal” green energy replenishment corridors for electric heavy-duty trucks. They are cited solely as industry background.)