A frequency-to-digital converter (FDC) performs the role of precise frequency digitization within a voltage-controlled oscillator (VCO)-based ADC. To be compatible with energy-harvesting (EH) Internet-of-Things (IoT) devices, the development of ultra-low-voltage (ULV) FDCs is crucial, where the primary focus must be directed towards the maximization of data throughput under dramatic constraints of reliability and timing variability associated with deep-subthreshold operation. This article investigates the speed maximization of a 0.2V full-custom ULV FDC design, consisting of an array of several parallel XOR-based FDC units, and the multi-rate decimation-filtering digital back-end. At the core of this broad exploration is a high-speed sense-amplify phase sampler (PS) featuring hardware redundancy, capable of sampling the phase of low-voltage-swing inputs. Particular focus is placed on the yield-based reliability-driven design methodology for the sense-amplify phase-sampling circuits running up to 40MS/s and practical variability-mitigation strategies. To overcome the speed bottleneck in the digital back-end, a fully parallel bitstream-processing architectural composition of the computations for summation and decimation are proposed. Experimental verification through measurements of the FDC integrated within a 10-bit 160kHz bandwidth (BW) open-loop VCO-based ADC across clock frequency with supply variations demonstrate robust operation of the first 0.2V multi-phase FDC in the advanced 28nm CMOS process.