Aluminium takes centre stage in Opsun’s new rooftop inverter racking system

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As commercial solar installations grow in scale, the supporting infrastructure around rooftop arrays is becoming an increasingly important area for engineered aluminium applications. North American solar mounting manufacturer Opsun Systems Inc. has added to this space with the launch of its SunRail Inverter Rack, a structural aluminium system developed to support string inverters on commercial and industrial (C&I) flat roofs.

The newly launched system brings inverter mounting into a standardised racking framework, addressing a part of rooftop solar installation that has often required project-specific solutions at the construction site. Opsun has begun immediate shipment of the product from its regional manufacturing operations in North America.

At the core of the rack is 6000-series structural aluminium, combined with 306 stainless steel bolts and nuts. The material configuration is engineered for rooftop environments exposed to significant wind and snow loading. Depending on the requirements of an individual project, the structure is rated for wind speeds of up to 180 mph and snow loads reaching 100 pounds per square foot (PSF).

The rack has been designed for low-slope roof surfaces with gradients of up to 7 degrees. A single standalone unit occupies approximately 15 square feet of rooftop area, while the base racking structure weighs 60 pounds. Depending on the installation arrangement, the resulting localised dead load on the roofing membrane ranges from 5 to 15 PSF.

Rather than limiting the system to a fixed inverter arrangement, Opsun has adopted a modular configuration capable of carrying one to six inverter units in each row. This allows the structure to be adapted to different electrical string layouts and project requirements.

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Installation efficiency is another focus of the design. Assemblies leave Opsun's regional production lines in a pre-assembled form, reducing the amount of work required at the project site. Across the structure, a single-nut hardware format has been standardised for connection points.

The rack is supplied with a standard inclination of 10 degrees, while projects requiring a different configuration can specify pitches of up to 20 degrees. Its mounting components move within integrated rail channels, enabling installers to adjust the system around uneven rooftop conditions, tapered insulation and other structural variations. This eliminates the need for project teams to undertake custom cutting or fabrication at the installation site.

Alongside the main structure, Opsun is offering an optional universal Inverter Cover made from folded aluminium. The accessory provides protection against direct solar radiation while maintaining an open-sided arrangement that allows ambient airflow around the inverter equipment for thermal management.

Maintenance requirements have also been considered in the cover design. Its integrated hood mechanism can be lifted to expose the internal wiring areas, giving technicians access to components without requiring removal or dismantling of the supporting rack.

The cover is compatible with large-format inverter equipment, including SolarEdge Three Phase Inverters with Synergy Technology in configurations ranging from SE80KUS to SE120KUS.

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The rack's base rails can also be integrated with several commercial rooftop attachment systems, including OMG, U-Anchor, S-5! and Facet systems. The mounting solution can be used across built-up roofs, thermoplastic polyolefin (TPO), ethylene propylene diene monomer (EPDM), asphalt surfaces and standing-seam metal roofing.

“What we kept hearing from EPCs was that inverter placement on the roof was still a field problem, no standardised solution, a lot of improvisation,” said François Gilles-Gagnon, president of Opsun Systems. “The SunRail platform lent itself well to solving that. The Inverter Rack is built on the same engineering logic: aluminium construction, engineered for real site conditions, and fast to install.”

Opsun manufactures its structural aluminium systems at facilities in High Point, North Carolina, and Cornwall, Ontario. Its portfolio covers solar mounting applications across commercial, industrial and residential projects, including flat roofs, pitched roofs, ground-mounted systems and carports.

For the aluminium value chain, the launch is another example of the metal's role extending beyond solar panel frames into the broader structural ecosystem of renewable-energy installations. In this case, aluminium forms the backbone of a rooftop system designed around load performance, installation flexibility and access for equipment maintenance.