That tells me you do not have the USPS January 2, 2011 C version installed ...
Please go to Module ... Shipping ...
1 click on USPS and save your current settings to NotePad ...
2 click on REMOVE
3 get the current file from post #26 of:
http://www.zen-cart.com/forum/showthread.php?t=171314
4 FTP the file in it usps.php to the directory:
/includes/modules/shipping/usps.php
5 Install the new USPS shipping module
6 Configure it with your settings
Now see if it works better ...
As a test, then go to the Tools ... Developers Tool Kit ... and in the bottom input box enter:
USPS GXG Envelopes
Select Catalog from the dropdown and click Search ...
What comes up now?


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