What version of the RoboClaw do you have(green pcb or red). If the board is faulty we will replace it. We just need to do some simple checking first. Describe the Analog circuit you used? If you have the red pcb roboclaw did you switch the jp3 jumper from 5v to 2v? Can you describe how you wired up for PacketSerial and what you used to communicated to it with(a PC or a microcontroller)? If you are using a PC are you using a level converter on the serial line? Have you tried using 2400 bps serial rates?
If you want a faster response go ahead and shoot me an email with the answers above.
nathan@basicmicro.com.