I cannot test all your DAQ stuff, because I don't have drivers installed. We need to narrow down the problem to what really matters.
The problem must be how you generate your DBL array as a function of the number of signals.
All the excel stuff works just fine as a function of how many cells are filled in the table. (see attached extract, LabVIEW 7.1)
Some troubleshooting suggestions:
Create an indicator at the DBL array right before you make the table. Run the program with various channel counts and after each run, click on that indicator and select "create constant". Give the constant an unique name, then place it on the attached VI. Collect a few of those, then post the VI.
It seems to me that as a quick&dirty fix you could just trim the array to the correct size.
(Also notice that you can eliminate one of your transpose operations. Remove both, then insert one right before the table indicator.)