Here is my config. I had to put require shipping on orders over $25,000 to make the checkbox show up, and I had to change it to a percentage to get a fee over $0. You can see it on www.koimillworks.com (in development). I changed it back to table rates.
Code:
Insurance
Enable Insurance Module
true
Offer Shipping Insurance?
true
Sort Order
500
Use Table Rates?
true
Alternate Insurance Type
amount
Insurance Percentage
1.6
Insurance Rate
$0.50
Increment Amount
$100.00
Amount Exempt From Fee
$0.00
Tax Class
--none--
No Insurance Fee on Virtual Products
true
No Insurance Fee on Gift Vouchers
true
No Insurance Fee on Free Shipping
true
Required Insurance Amount
$25,000.00
Insurance Zone 1
--none--
Zone 1 Insurance Table
50:1.65,100:2.05,200:2.45,300:4.60,:400:5.50,500:6.40,600:7.30
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