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Are the levels your sending to your BFDs generally provide level indication on the from panel?
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Generally yes, to obtain the best S/N you want to take full advantage of every bit available in the BFD. The bit resolution defines the dynamic range of any digital system and so the signal to noise ratio is maximized by using as much of the dynamic range as possible. If the range from your weakest signal to the strongest signal was only half the required maximum input level, you would be robbing yourself of dynamic range and subsequently worstening your signal to noise level.
But in my tests, output signals remain linear even with extremely low input levels (an inherant problem with ADC's) across the full audio band and doesn't distort until you're slightly above the red clipping led.
Again I have to say you appear to have a fault. Perhaps you could exchange it for a new unit.
brucek