Error on orders with Free Shipping

To simplify things I used a clean install of version 1.5 of osC MAX

I simply chose one product, set its weight to 0 in administration.
The 0 weight gave free shipping for the product.

The problem lies with the emails for both the merchant and customer with the shipping address coming through as a comma , and also the shipping address blank in the orders area for this customer's order in orders history.

If the customer orders products where he ends up paying shipping, this problem does not occur.

Is there a solution for this problem?

Thanks,

Gary