Design of the PFC module for the AC-to-DC converter is nearly complete. Each module provides a 1kW output at 340V with a power factor of 0.99 and an output efficiency of 96% with an input voltage of 240 VAC. These modules can be combined in parallel to provide higher output power. Each of these boards contains two non-isolated buck-boost converters that can operate over an input range of 120 - 410 VDC or 90 -270 VAC with an external rectifier and EMI filter. The two converters are operate out-of-phase with each other to minimize EMI and the capacitor ripple currents. Each of these boards are controlled from a central board that provides the reference clock and feedback for limiting the output voltage when the output is not sufficiently loaded.
I plan to have the board and BOM finalized by the end of the week. I hope to build and test a single PFC module near the end of next month.