Well, rysher's suggestion to call Mean Well was a great one as the issue is solved - at least the reason for it.
The 50% max dimming mentioned before in this thread and others is the cause. As discussed previously, the datasheet for the HLG's was changed. This is because the drivers themselves were changed. For the 240's, it was around July 2011. I happen to have received earlier versions where the only dimming is with a resistor and is not linear. If you look at an old datasheet you'll know what I mean. Long story short - my 48v 240 is 100% with an open dimming circuit, 75% with a 620 ohm resistor or 50% with a 68 ohm resistor. The 54v version uses 820 ohm and 150 ohm resistors for 75% and 50% respectively.
TBH, this sorta sucks. I was really wanting to take advantage of the 1vdc-10vdc dimming. Not sure what I'm going to do at this point but I'm thinking with just using the 3 ELN's I already have instead. If anyone is interested in a great deal on the restricted dimming 240's just let me know.
The tech mentioned that to be completely sure you'll want to get a unit made Aug 2011 or later.
At least it wasn't my build. I was starting to think I was crazy!