Bummer. You score zilch. From the config option itself, it states
"Carriers have a max weight limit for a single package" . (not per customer).
The theory seems sound, but what happens if any single item in your store weighs more than 500gm, if if the dimensions happen to be too large? You haven't left yourself any fallback method.
Also, by setting this as a global limit you are actually defeating all of the 'brain power' of the AP module itself, and you will probably be better off using a price per item shipping method (after all, that is effectively what you seem to be aiming for).
Nonetherless, this still has me curious in regards to explaining the results you are getting with the AP module.
I do believe you have stumbled across a rather unique set of configurations that allows things to 'fall through the gaps'.
Please don't bow out on me now... There is a solution to this odd behaviour, but I/we need to work out the cause of it first.
I do this by typing out my thought processes in these replys. :-)
The fact that Regular parcels 'works a charm' eliminates a lot of possible causes.
What makes the difference between a regular parcel and a prepaid satchel (from the perspective of the AP module)?
Simple answer... weights and/or dimensions.
You have already indicated that the parcel dimensions are within the limits of a 500gm satchel, so that now only leaves one possible place left ... weights.
As mentioned in the Austpost docs (and elsewhere in these forums) Weight additions and calculations are not a function of the shipping modules.. they are performed by zencart itself (bear with me).
What the shipping module recieves to calculate on are the number of parcels and the weight of those parcels.
You have set your max shipping weight to 500gm (I still don't know the weight of your test product(s)), but if you happen to place a 500gm product in your cart, and you have zero tare weight, the zencart weight code would accept this as being within limits, and the shipping module will be asked to quote on 1 parcel weighing *exactly* 500gms. If you place a 1kg item in your shopping cart the zc code will honour your max weight limit and the shipping module will be asked to quote on 2 parcels weighing *exactly* 500gms each.
The AP module always errs on the side of caution, and will consider 500gm too close to the borderline to travel at 500gm or less rates, and will declare this product to be too heavy for the 500gm satchels. If no other suitable shipping methods are enabled you'll get the cant get a valid quote error message.
I'd assume that if you have the 3kg satchels enabled they *would* show up.
I'd also assume that if you drop your product weight and/or your maximum shipping weight to 499gm you'll find the satchels will then (probably) show up.
If your product weight was 499gm, and your tare weight was 1gm the satchels would not show up.
As you can see, I'm still making assumptions here (I still have no product weight data or URL to check or verify this)
I probably did you no favours earlier when I responded to your question in the way it was written, namely by tellling you how to do what your asked, rather than trying to find out what you was trying to do (or why you felt the need to do it).
On the other hand, you were explaining a whole lot of totally different problems back in the first message (regualr parcel quotes being way too high).
Seriously though, I do think that that nice round magic number '500' is probably the explanation to some of what you are seeing, and I do think you need to re-evaluate what you need or require in regards to shipping... If you really do only wish to allow prepaid satchels only, and with only one item per satchel then the cost per item shipping rates will be far more suitable to your needs... if for no other reason than it won't be dependent on other servers in order to provide quotes.
However, if you have a somewhat varied range of products and you are happy to combine shipping on any and all products in the shopping cart without having to worry about 'what will it fit into'
then the AustPost module is the way to go, but to get the most out of it you will need to give it the maximum flexibilty possible.. in other words you *will* allow parcels up to 20kgs to be acceptable (don't try to force everything into a 500gm bags)
You should only dissallow shipping methods that you explicitely do NOT want. Eg, COD.
Then all being well, no matter what products or how many items a customer places in the cart, the AP module will only show those options applicable to that *package*.
Lemme know if my current assumtptions and guesswork is on the right track, and PLEASE include a URL if not.
Cheers
Rod