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Herein, a novel methodology to perform optimal sizing of AC-linked solar PV-PEM systems is proposed. The novelty of this work is the proposition of the solar plant to electrolyzer capacity ratio (AC/AC ratio) as optimization variable. The impact of this AC/AC ratio on the Levelized Cost of Hydrogen (LCOH) and the deviation of the solar DC/AC ratio when optimized specifically for hydrogen production are quantified. Case studies covering a Global Horizontal Irradiation (GHI) range of 1400–2600 kWh/m2-year are assessed. The obtained LCOHs range between 5.9 and 11.3 USD/kgH 2 depending on sizing and location. The AC/AC ratio is found to strongly affect cost, production and LCOH optimality while the optimal solar DC/AC ratio varies up to 54% when optimized to minimize the cost of hydrogen instead of the cost of energy only. Larger oversizing is required for low GHI locations; however, H 2 production is more sensitive to sizing ratios for high GHI locations. • The AC/AC ratio (PV-inverter to PEM capacity) is proposed as optimization variable. • Low solar resource leads to large solar plant oversizing and high AC/AC ratios. • In Atacama, Chile, an AC/AC = 1.2 & DC/AC = 1.3 leads to an optimal LCOH = 5.9 USD/kg. • In Fargo, N. Dakota, an AC/AC = 1.4 & DC/AC = 1.8 leads to an optimal LCOH = 9.7 USD/kg. • The optimal PV plant DC/AC can vary up to 54% if minimizing energy or hydrogen cost. [ABSTRACT FROM AUTHOR]