Assume that there is a reason that 60 amps (or so) output is picked for a reason in Brand Other charge controllers...
4:1 voltage drop / 1:4 current...
200-550 vdc working voltage input
200vdc/4 * 60 amp output = 50 vdc * 60a = 3kW
550vdc/4 * 60 amp output = 137.5 vdc * 60a = 8.25 kW
Then there is my system running at ~300-320 VDC peak (of course, we all know that "my" system is the average system out there and the new product should work perfect with "my" system.
320/4 * 60 amp = 80 vdc * 60a = 4.8 kW
My system is an ~3 kW STC system, so 60 amp is way over the available power... perhaps even cutting this to 30 amp maximum output would be perfectly OK (assuming that people with larger arrays could parallel 4:1 converters).
We look at a "Brand Other" Mx-60 runs around $500-$650 each.
That is approaching ~$1.00 per watt at 12 vdc (assuming I remember everything correctly in that this is 60 amp * 12 vdc = 720 watts), but only ~$0.25 per watt for a 48 vdc battery bank. Obviously, when first introduced can charge more than as the product gets more competition.
Since the output power is highly dependent on the input voltage--picking a price point like $1.00 list, and $0.50 wholesale/volume buys does not make sense...
And looking at the pricing for the Mx-60... Pick 24 vdc battery bank. 24v*60=1,440 watts. Makes list price around $0.50 per watt. The solar panels are ~$5.00 per watt, so the "piece of equipment" is around 10% of the panel price.
Going back to my 320 volt / 4 @ 30 amps--that would be 2,400 watts or $12,000 list for panels. 10% of that would be $1,200 or $0.50 per watt...
$1,200---I would guess would be the high end price for a 30 amp output unit... Perhaps a smaller sized 4:1 converter unit, say 15 amps @ $600, would be a better price point for entry level converter.
The Honda eu2000i (1,600 Watt continuous rating) Internet price is around $900 (or a bit less) delivered. $1,200 for 2,400 Watts using solar power that would otherwise be wasted seems like a good price point.
Now, the prices I listed above are assuming a minimum function stand-a-lone unit. But, because it does something that nothing else does--I would think it could get some attention in the market. If it could be listed for 1/2 of the above price--(say 1/2 the price of a Mx-60 controller)--it would become very interesting to many more folks.
Now, whether this unit should be a stand-a-lone unit or combined as an optional input module for a Xantrex Solar Charge controller--something that marketing could work out.
Also, I gave the above as a maximum price, I would guess, the market will support for a one-of-a-kind product. If the manufactured price supports a lower list price--combining with other functions (such as a full fledged MPPT charge controller) may help keep margins up and lock the market to the one SGT unit.
Now, efficiency... 1st assumption is that this is a double conversion unit for emergency use--so that 0.93*0.93=86% is a guess at the approximate "best" efficiency one could get from this unit. It is possible that cost of copper wiring and the fact that I squared R wiring losses would be 1/16 of a low voltage controller may help some folks that have to place panels in the sun quite a distance from point of use.
If the list price is kept low, and this is assumed to be a generator replacement (auto-switch would be nice--may have to sync with GT LINK?), efficiency is not going to be the big seller...
And, as a "standby" battery charging system, if the efficiency is much less than 85%, then simply using a 120/240 VAC charger for battery maintenance (and maybe charging with that cheap emergency gas generator) would be more efficient anyway.
But, have to be careful of the added costs (Converter, Solar Charge Controller, possible AC Mains Battery Charger, possible backup-backup fuel driving generator)...
I will stop typing here... Anything of interest yet?
-Bill