This is probably caused because the Australia Post server has been offline for most of the day (17 May 2008).
I dunno. This isn't really an AP module issue, it is a zencart issue. The Aust Post module will quote (or not quote) according to the data passed to it by the core zencart code. It knows nothing at all about free shipping or any other kind of non AP shipping options.
Cheers
Rod




