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Master Volume Knob Affects Headphone Volume / Headphone Port 2 Configuration
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Q) The Master Volume knob affects my headphone volume, how do I fix this?

 A) The headphone volume is linked to the master volume knob. If your master volume is turned down, you will get little to no headphone volume. The ProFire control panel provides for flexible routing and control over the audio paths via onboard DSP.  
The Control Panel features five mixer tabs along the top of the window (Analog Out 1/2, 3/4, 5/6, 7/8, and S/PDIF Out L/R). Use these tabs to select the output for which you’d like to create a monitor mix. This monitor mix can include the output of your software and any of the analog inputs on the ProFire 610. For example, select the “Analog Out 7/8” tab to create a monitor mix that routes to analog outputs 7 and 8. Note that the two headphone outputs on the front panel of ProFire 610 correspond to Analog Outputs 1/2 and 3/4, respectively. 
If you don't want to the headphone volume to be linked to the Master Volume control, connect your speakers to line outputs 5 and 6 on the back of the 610. Then go to the Settings tab of the ProFire 610 control panel and set the Master Volume Knob to Analog Out 5/6 only. (see picture below)
Warning: Unchecking one of the Master Volume Knob boxes allows its corresponding
outputs to play at full volume (i.e., without any attenuation). This may result in very loud signals being sent to your speakers, headphone amplifiers, or other equipment.
Now, click on the Analog Out 5/6 tab and turn up software returns 1 and 2 (faders 7 and 8). Once you have done this, the headphone volume will be independent of the Master Volume control (speakers).
Headphone port 2 mirrors Analog Out 3/4. If you need headphone port 2 to be the same audio as headphone port 1, turn up software returns 1 and 2 in the Analog Out 3/4 mixer