I recently replaced an 11 year-old Audiobox USB whose left main output had died a few years ago. It was the output itself; the rest of box functioned, so I just took an insert cable and ran an unbalanced connection from the headphone jack to my powered speakers which did work fine and still works fine. Since I just upgraded to a new computer a month ago, I bought a new Audiobox USB96 because the old one was starting to lose connection and I had to continually restart the audio service either by software reset or by pulling and re-seating the USB cable. With those caveats aside, it worked on multiple machines, including another running Windows 10 and never had any level or clipping problems.
I installed my new USB96 and and works as expected with one major exception: regardless of signal level, if I run my Windows audio level above 90%, the unit clips its output and pops and crackles. This is true across all content from all sources. I have multiple high-end audio editors that can confirm no signal clipping is occurring within the files themselves. I would just turn down to 90% and leave it, but I also notice that the signal tonality changes significantly with volume. My old box never did that with the same monitors on this new computer and still doesn't do that when I change them out to test, so it leads me to conclude it is a hardware/driver issue. Has anyone else encountered this and if so, were you able to solve it?