uspsv5::list_rates() - shipment->populate() failed!

[vsionquest]

Having an issue of not being able to figure out why the shipping options are not displaying with USPSv5 on VM 1.1.9 on joomla 1.5.23.   The figures seem to be returned ok in the XML statement but the values are blank to the display unless you enable debug, at which point you get the following messages:


Please select a Shipping Method!
uspsv5::__construct() - Starting module version 5.2011.02.10
uspsv5::list_rates() - Starting
Shipment::addPackage() Adding a new unbundled package
Shipment::addPackage() - Package Number: 1
Shipment::addPackage() - Package is Unbundled
Shipment::addPackage() - Maxweight: 70
Package::addItem() - WARNING - product dimensions assumed to be INCHES
Package::query_rates() - Querying for Source: US/91307 , Destination: US/95131, Weight: 1.02, Value: 20
uspsv5::get_rates_array() - GXG service selected. Forcing dimension declaration.
uspsv5::get_rates_array() - Calculating domestic shipping.


XML Post:
http://production.shippingapis.com/ShippingAPI.dll?API=RateV4&XML=<RateV4Request USERID="***********" ><Revision /><Package ID="0"><Service>All</Service><ZipOrigination>91307</ZipOrigination><ZipDestination>95131</ZipDestination><Pounds>1</Pounds><Ounces>1</Ounces><Container /><Size>REGULAR</Size><Machinable>FALSE</Machinable></Package></RateV4Request>


XML Result:
<?xml version="1.0"?>
<RateV4Response><Package ID="0"><ZipOrigination>91307</ZipOrigination><ZipDestination>95131</ZipDestination><Pounds>1</Pounds><Ounces>1</Ounces><Size>REGULAR</Size><Machinable>FALSE</Machinable><Zone>3</Zone><Postage CLASSID="3"><MailService>Express Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt;</MailService><Rate>23.85</Rate></Postage><Postage CLASSID="2"><MailService>Express Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Hold For Pickup</MailService><Rate>23.85</Rate></Postage><Postage CLASSID="55"><MailService>Express Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Flat Rate Boxes</MailService><Rate>39.95</Rate></Postage><Postage CLASSID="56"><MailService>Express Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Flat Rate Boxes Hold For Pickup</MailService><Rate>39.95</Rate></Postage><Postage CLASSID="13"><MailService>Express Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Flat Rate Envelope</MailService><Rate>18.95</Rate></Postage><Postage CLASSID="27"><MailService>Express Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Flat Rate Envelope Hold For Pickup</MailService><Rate>18.95</Rate></Postage><Postage CLASSID="30"><MailService>Express Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Legal Flat Rate Envelope</MailService><Rate>18.95</Rate></Postage><Postage CLASSID="31"><MailService>Express Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Legal Flat Rate Envelope Hold For Pickup</MailService><Rate>18.95</Rate></Postage><Postage CLASSID="1"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt;</MailService><Rate>5.65</Rate></Postage><Postage CLASSID="22"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Large Flat Rate Box</MailService><Rate>15.45</Rate></Postage><Postage CLASSID="17"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Medium Flat Rate Box</MailService><Rate>11.35</Rate></Postage><Postage CLASSID="28"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Small Flat Rate Box</MailService><Rate>5.35</Rate></Postage><Postage CLASSID="16"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Flat Rate Envelope</MailService><Rate>5.15</Rate></Postage><Postage CLASSID="44"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Legal Flat Rate Envelope</MailService><Rate>5.30</Rate></Postage><Postage CLASSID="29"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Padded Flat Rate Envelope</MailService><Rate>5.30</Rate></Postage><Postage CLASSID="38"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Gift Card Flat Rate Envelope</MailService><Rate>5.15</Rate></Postage><Postage CLASSID="42"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Small Flat Rate Envelope</MailService><Rate>5.15</Rate></Postage><Postage CLASSID="40"><MailService>Priority Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt; Window Flat Rate Envelope</MailService><Rate>5.15</Rate></Postage><Postage CLASSID="4"><MailService>Parcel Post&lt;sup&gt;&amp;reg;&lt;/sup&gt;</MailService><Rate>5.65</Rate></Postage><Postage CLASSID="6"><MailService>Media Mail&lt;sup&gt;&amp;reg;&lt;/sup&gt;</MailService><Rate>2.89</Rate></Postage><Postage CLASSID="7"><MailService>Library Mail</MailService><Rate>2.75</Rate></Postage></Package></RateV4Response>

Package::query_rates() - Rate query returned null results.
Shipment::populate() - query_rates() failed.
uspsv5::list_rates() - shipment->populate() failed!

Notice: We are unable to ship via USPS at this time. System Error.

For some reason this used to work until another shipper was added.  Now I have removed all except USPSv5 and still am getting this error message shown above.

Anyone able to offer help on solving this?  Thanks if you can.