Such errors also happened with the old system - for years now. Have you tried pirateship as an option for when its down for an extended period of time? You can import your eBay orders there and printe labels. Commercial pricing, cubic pricing, $100 insurance.
I have noticed a pattern over the years. If I immediately withdraw my PayPal payment for the item(s) and attempt to print a label right away using my non eBay/PayPal credit card it dramatically increases the chances of an error occuring. If I wait a few minutes after withdrawing the PayPal payment before I attempt to create a label then errors are greatly reduced.
If I use the PayPal balance or eBay/PayPal's credit card to pay for the label then few errors occur. PayPal has went out of its way to make paying for labels with your non eBay/Pal credit card more difficult in the past - for instance, in the past you could only charge to your card if your PayPal balance was zero - forcing you to withdraw all your funds before using your card. I am wondering if this some historic technical glitch related to this. Of course maybe its intentional - just look at their new withdraw system and tries to con you into paying for a faster withdraw. :0)
