Sometimes customers allowed Free shipping (not supposed to be)

Hello,
Some customers get the option to display free shipping at check out. I replicated it by adding two items to my cart in exact quantities which were like 2 of each.

So when I add or subtract QTY of one from one of the items, doesn't matter which one, free shipping disappears. So I am at a loss as to where this is somehow calculating it. I also noticed an order that came through with free shipping that only had one product in it. I don't have any coupons for this setup, so thats not it.

I am loosing money every once and awhile on orders because of this.

Any help or ideas ASAP is appreciated
Thanks
Jamey

What are the conditions for your free shipping?
What shipping module are you using to control this?
What version of ZenCart are you using?

Thanks for the quick reply! Just the FREE SHIPPING/freeshipper Module is active(I think they are default). Never seen the free shipping options module that is above it before, but it is currently inactive/not installed. Below are the only options in FREE SHIPPING Module. I also have UPSXML + USPS installed.

FREE SHIPPING

Enable Free Shipping
True

Free Shipping Cost
0.00

Handling Fee
0

Tax Class
--none--

Shipping Zone
--none--

Sort Order
0

It's probably something to do with the weight of the products and the shipping rates table. What shipping mods are you using?

Here is something odd unless I am missing something or this is possibly a bug. Here is what I have done.

This occurs when the following order is in the cart.
QTY1 of Product 1 (Downloadable product)
QTY1 of Product 2
=Free shipping option available to be selected.

QTY4 of Product 1 (Downloadable product)
QTY4 of Product 2
=Free shipping option available to be selected.

QTY1 of Product 1 (Downloadable product)
QTY2 of Product 2
=NO Free shipping option available to be selected.

QTY2 of Product 1 (Downloadable product)
QTY1 of Product 2
=NO Free shipping option available to be selected.

As you can see if the quantities of the two products go up in equal amounts the free shipping option shows. If I change weight of these items in the store or change the price of either one it does not make a difference in any way when the FREE shipping appears. Per weight,freeoptions,table rate and per item shipping options are not enabled.

I can seem to fix it by changing the downloadable product with the setting below from yes to no.
Product is Virtual:
Yes, Skip Shipping Address
No, Shipping Address Required

This is very strange and I have been racking my brain. I am not a PHP coder, but I believe this could be a bug with Zencart, so if anyone could check this with your cart and a download product that would be great.

Downloads are NOT Virtual Products and NOT Always Free Shipping ... they know there isn't shipping based on the filename on the Attribute ...

Make sure you set:

Product is Virtual: **No, Shipping Address Required **

Always Free Shipping: No, Normal Shipping Rules

Ok thanks, I guess I misunderstood what virtual products are.