I've got the changes needed to properly handle orders with all virtual products uploaded to the plugin's GitHub repository. It turns out that the same issue presented itself if your store uses the free-shipping configuration associated with the shipping order-total (your admin's Modules->Order Total->ot_shipping).
You can grab those latest changes from the plugin's master while I determine if there are any other gremlins waiting to be squished. The plugin's admin auto-initialization will update the One-Page Checkout version to 1.0.4-beta1.
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