In addition to the USB cable, are you using an audio cable to run the sound into the PC or do you have a modified PCR that send data AND sound via USB?
Classic version 2.5 uses a different encoder than the current version of Recast because of strange issues like the one you are describing popping up every once in a while.
I'm sure that support would be interested in hearing one of your files, we probably won't spend an extraordinary amount of time on it since that product isn't sold anymore. We realize that there are reasons that some users prefer to stay with the earlier versions and that is fine with us, however we are focused on moving Recast forward.
David K.
Time Trax Customer Service