It is not clear how you are allocating the array.
I am assuming your are using TestStand 2.0. Take a look at the example C:\TestStand201 backup\Examples\AccessingArrays\UsingLabVIEW. In this example you will find that the Locals.StringArray in a array variable that is initially set to empty. The Set String Array step in the MainSequence calls a VI that populates Locals.StringArray. TestStand dynamically resizes the array to accept the array that is sent back.
You could alternatively use "TestStand - Get Property Value (Object).vi" from the TS funtion palette to get a reference to the array. Then, using a LV invoke node, you could call SetNumElements or SetDimensions on the array reference before writing your array back to your sequence. To prevent a leak, ma
ke sure that you use an Automation Close function to close the ActiveX reference to the array if you choose to get one.
Let me know if you have questions.