This article presented a reconfigurable bi-directional single-stage interleaved totem-pole electrolytic capacitor-less converter designed for fast charging applications. The proposed converter has high-power capability, and a wide voltage range operation to accommodate various types of electric vehicles. In addition, the converter efficiency and power quality are further improved by optimizing control variables; phase shift, switching frequency, and the secondary duty cycle is optimized to achieve low-grid current THD, conduction loss, and switching loss. Full ZVS turn-on is achieved from 150 to 920V battery voltage. Experimental results from the 7.4 kW EV charger prototype are provided to verify the theoretical claims. The peak efficiency of 96.8% is achieved at 1kW power, 120V grid voltage, and 200V battery voltage. Furthermore, this converter exhibits flat efficiency performance in entire battery voltage ranges.
