This paper outlines the design process of a high-efficiency (99.5% peak) transformerless DC EV fast charger in conjunction with relevant UL standards on conducted harmonics and leakage current. The topology is a non-isolated transformerless design which allows for the elimination of the additional transformer volume and losses that are present in galvanically isolated topologies. Methods for calculating optimal switching frequency and inductance to minimize loss as a function of chosen switching device and power level are provided. Filter sizing and component values are chosen in conjunction with the previously determined optimal switching frequency and inductance. Heatsink design rationale are then derived. Experimental efficiency, switching waveforms, and output voltage and current quality results are provided. Industrial topology feasibility is shown through experimental adherence to relevant UL, IEC, IET, and IEEE standards.
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