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,i can only think its because of the sound cards output being totally different between digital and analogue
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I don't see that being a problem even if it was indeed at a different level, because it would be compensated for in the setup.
In the Settings screen when you run the Check Levels routine, you first adjust the RS SPL meter at the listening position to 75dB with the REW output level and the receiver volume control. Then you adjust the REW input level to the correct level.
Then you run the Calibrate SPL routine in REW to match that 75dB level.
That's it, it's all at the correct level. The only problem after that would be that you don't have the End Frequency adjusted in the Measurement routine screen matching the pink noise cutoff frequency in the Check Levels routine in the Settings screen.
If you do a Check Levels in the Settings routine for a subwoofer, the hi-cut on the pink noise is 80Hz. If you set the End Frequency in the Measurement routine to (for example) 400Hz and tested the Check Levels there, you would get an incorrect reading on the levels. Be sure the upper End Frequency in the Measurement routine is at 200Hz.......
brucek