Seems the only two common denominators are the BDDI and the AC supply. I would say it could very easily be the supply and would try another one as well as try using batteries.
My guess is that perhaps the OP is trying to get more volume than the speaker system can handle. The BDDI can't make a power amp fail. If it was malfunctioning it wouldn't sound right. It can push the power amp harder than it should be if used incorrectly.
Internal fans on my amp will be running high & the amp itself will get PRETTY warm.
All this indicates that the power amp is being pushed too hard.Volume-wise, I`m finding that for some reason, I`m having to run everything pretty loud to hear it...
Hopefully the OP will let us know his settings. Here are some facts.
There is a 4 Ohm 200 watt cab and an 8 Ohm 400 watt cab.
The GK400RB is only rated at 240 watts @ 4 Ohm and 150 watts @ 8 Ohm.
The Crown is rated @ 350 watts @ 4 Ohm and 215 watts @ 8 Ohm. If used bridged it is too much power for either cab.
It really depends on the situation and how loud the band is. Loud drummer and 2 guitar players will probably be tough to keep up with using only one 200 watt cab or an under powered 400 watt cab.
My suggestion would be to either use the two 4 ohm cabs with the Crown and be careful with the volume. The OP could also bridge the Crown and use the 8 Ohm 400 watt cab but he would have to be careful with that as well. I would also suggest when using the Bass Driver with the GK to use the input pad as the Bass Driver can easily drive the amp too hard whether or not the overload light comes on.
Wattage only refers to the amount of heat your speakers will take before they burn out. SPL is how "loud" the cab actually is.