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if the solution is to leave the unit on all the time will this be harmful?
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No, it won't be harmful or expensive. I haven't turned my BFD off for years. I measured it and it dissipates 7watts. That's a night light........ I see the spec for the FDB is 10 watts...... insignificant. A lot of the devices in your home when shut off still leak that much keeping clocks running etc.
But that's not really the issue. There must be a function set that you're not familiar with yet. I certainly take all the filters in the program I'm using in the BFD and set them all to off. I don't want it to act like a feedback destroyer..... Perhaps set all the unused filters to OFF.
It that or you actually have a fault... I would think you could get a warranty replacement without much trouble.
brucek