Sorry to flood this thread with messages, Paul, but this is getting quite ridiculous. I'm currently balancing my template and it's almost quaranteed that the noise burst happens at least once in every session (I reinstalled VEPro 6). I know you guys are doing what you can, but do you have any idea about what might help? Even with the safety measures I've taken it's quite hard to ignore the issue when my meters are flashing red.
Thought I would chime in as this issue still exists after years...though it is a bit better. It blew a very expensive JBL tweeter a couple of years ago for me.
Here is what we have figured out on our end.....If you have an instrument like Kontakt and you are using multiple outs.....group them together so when you enable/disable all the outputs get enabled/disabled together. If you leave the additional outputs not in the group and the main output gets disabled but not the additional outputs you are very likely to get the bursts that will blow your speakers.
Also....never disable an instrument until absolutely no sound is playing anymore. If there is still sound it is like the buffer gets stuck and when you re-enable....look out....bursts of sounds are likely.