We had a similar issue, which had more to do with the construction of the house 
than the rail span.  The system was on a 40' long array, but we had an 
expansion 
joint every 11' or so.  The issue with our popping sound mirrored yours (it 
would cause the noise in the morning and into the evening.  At our site, the 
noise occured at a location where a new addition had been attached to an older 
structure, and were not fastened together properly.  We resolved the issue by 
isolating the rail sets from each other where the two structures met.

 Nick Soleil
Project Manager
Advanced Alternative Energy Solutions, LLC
PO Box 657
Petaluma, CA 94953
Cell:   707-321-2937
Office: 707-789-9537
Fax:    707-769-9037




________________________________
From: Darryl Thayer <daryl_so...@yahoo.com>
To: RE-wrenches <re-wrenches@lists.re-wrenches.org>
Sent: Mon, August 30, 2010 10:02:35 AM
Subject: Re: [RE-wrenches] roof noise after solar install.

The roof is trusses, and OSB on top and comp shingles, one layer

--- On Mon, 8/30/10, hol...@sbcglobal.net <hol...@sbcglobal.net> wrote:

> From: hol...@sbcglobal.net <hol...@sbcglobal.net>
> Subject: Re: [RE-wrenches] roof noise after solar install.
> To: "RE-wrenches" <re-wrenches@lists.re-wrenches.org>
> Date: Monday, August 30, 2010, 8:42 AM
> Darryl,
> Just thinking.....wonder if the roof expansion along with
> the rail expansion 
> are creating the issue....what kind of decking, roofing
> material is 
> involved? It may be that the combination of the two might
> require a joint 
> even though you haven't exceeded the 30' limit....just
> guessing.
> 
> Holt E. Kelly
> Holtek Fireplace & Solar Products
> 500 Jewell Dr.
> Waco TX. 76712
> 254-751-9111
> www.holteksolar.com
> 
> ----- Original Message ----- 
> From: "Darryl Thayer" <daryl_so...@yahoo.com>
> To: "RE-wrenches" <re-wrenches@lists.re-wrenches.org>
> Sent: Monday, August 30, 2010 8:34 AM
> Subject: Re: [RE-wrenches] roof noise after solar install.
> 
> 
> Thanks I missed that, but my longest run is just under 30'
> I would think 
> this requires an expansion joint at 20' or longer?
> Darryl
> 
> --- On Mon, 8/30/10, hol...@sbcglobal.net
> <hol...@sbcglobal.net>
> wrote:
> 
> > From: hol...@sbcglobal.net
> <hol...@sbcglobal.net>
> > Subject: Re: [RE-wrenches] roof noise after solar
> install.
> > To: "RE-wrenches" <re-wrenches@lists.re-wrenches.org>
> > Date: Monday, August 30, 2010, 8:29 AM
> > Not looking at Unirac's install
> > manual, but I'm pretty sure it says
> > something like "expansion joint may be required in run
> of
> > 30' or
> > longer"....I'm guessing that means one per 30'
> run....I
> > would verify with
> > them......they have expansion joint plates.
> >
> > Holt E. Kelly
> > Holtek Fireplace & Solar Products
> > 500 Jewell Dr.
> > Waco TX. 76712
> > 254-751-9111
> > www.holteksolar.com
> >
> > ----- Original Message ----- 
> > From: "Darryl Thayer" <daryl_so...@yahoo.com>
> > To: "RE-wrenches" <re-wrenches@lists.re-wrenches.org>
> > Sent: Monday, August 30, 2010 8:21 AM
> > Subject: Re: [RE-wrenches] roof noise after solar
> install.
> >
> >
> > How frequently would you suggest? I have none at this
> > point, and where to
> > get joint and where to place?
> >
> > --- On Mon, 8/30/10, hol...@sbcglobal.net
> > <hol...@sbcglobal.net>
> > wrote:
> >
> > > From: hol...@sbcglobal.net
> > <hol...@sbcglobal.net>
> > > Subject: Re: [RE-wrenches] roof noise after
> solar
> > install.
> > > To: "RE-wrenches" <re-wrenches@lists.re-wrenches.org>
> > > Date: Monday, August 30, 2010, 7:55 AM
> > > Expansion joint in rails?
> > >
> > > Holt E. Kelly
> > > Holtek Fireplace & Solar Products
> > > 500 Jewell Dr.
> > > Waco TX. 76712
> > > 254-751-9111
> > > www.holteksolar.com
> > >
> > > ----- Original Message ----- From: "Darryl
> Thayer"
> > <daryl_so...@yahoo.com>
> > > To: "newrewrenches" <RE-wrenches@lists.re-wrenches.org>
> > > Sent: Sunday, August 29, 2010 8:08 PM
> > > Subject: [RE-wrenches] roof noise after solar
> > install.
> > >
> > >
> > > > New roof asphalt shingle, 5.1 kW system,
> string
> > > inverter makes roof noises in the morning, and
> > afternoon
> > > particularly after dark
> > > >
> > > > Creek and crack it finally stops late at
> night
> > but
> > > restarts late morning and stops mid afternoon
> most
> > days then
> > > intensifies after dark. Timing seems to follow
> > > temperature, has customer freeked
> > > >
> > > > Longest tun is 30 feet Unirack rail with
> top
> > down
> > > clamps.
> > > > Darryl
> > > >
> > > >
> > > >
> > > >
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