Requires country

I'll look into it. So to make sure I'm clear, the address itself is not required and the field is disabled, right? Do you have a default country specified?

Try replacing the following function with this code:

function theme_cck_address_display($form) {
  $output = '';
  asort($form['field_order']['#value']);
  foreach ($form['field_order']['#value'] as $field => $order) {
    if ($form['fielddisplay']['#value']['field_display_'.$field] === 'field_display_'.$field) {
      $output .= drupal_render($form[0][$field]);
    }
    else {
      if ($field == 'country' || $field == 'state') {//make it so if activeselect isn't used that we do make #access FALSE instead of this
        $form[0][$field]['#title'] = '';
        $form[0][$field]['#attributes'] = array('style' => "display:none");
      }
      else {
        $form[0][$field]['#access'] = FALSE;
      }
    }
  }
  $output .= drupal_render($form);
  return $output;
} //function theme_cck_address_display()

Sorry it isn't a proper patch.

And for the node display, try replacing this function too:

function theme_cck_address($cck_address, $field) {
  //create the output
  if ($cck_address['afd'] == 1) {
    $output = $cck_address['street1']. ' ';
    $output .= $cck_address['street2']. '<br />';
    $output .= $cck_address['city']. ', ';
    $output .= $cck_address['state']. ' ';
    $output .= $cck_address['zip'];
    $output .= '<br />';
  }
  else {
    $output = '';
    asort($field['field_order']);
    foreach ($field['field_order'] as $field2 => $order) {
      switch ($field2) {//TODO create more elaborate output based on $order; not I'm only now using it for display of other, assuming it will either be first or last
        case 'street1':
          if ($field['fielddisplay']['field_display_street1'] === 'field_display_street1' && isset($cck_address['street1']) && $cck_address['street1'] != '') {
            $output .= $cck_address['street1'] .' ';
          }
          break;
        case 'street2':
          if ($field['fielddisplay']['field_display_street2'] === 'field_display_street2' && isset($cck_address['street2']) && $cck_address['street2'] != '') {
            $output .= '<br />'. $cck_address['street2'];
          }
          break;
        case 'apt':
          if ($field['fielddisplay']['field_display_apt'] === 'field_display_apt' && isset($cck_address['apt']) && $cck_address['apt'] != '') {
            $output .= '#'. $cck_address['apt'];
          }
          break;
        case 'city':
          if ($field['fielddisplay']['field_display_city'] === 'field_display_city' && isset($cck_address['city']) && $cck_address['city'] != '') {
            $output .= '<br />'. $cck_address['city'] .', ';
          }
          break;
        case 'state':
          if ($field['fielddisplay']['field_display_state'] === 'field_display_state' && isset($cck_address['state']) && $cck_address['state'] != '') {
            $output .= $cck_address['state'] .' ';
          }
          break;
        case 'zip':
          if ($field['fielddisplay']['field_display_zip'] === 'field_display_zip' && isset($cck_address['zip']) && $cck_address['zip'] != '') {
            $output .= $cck_address['zip'];
          }
          break;
        case 'country':
          if ($field['fielddisplay']['field_display_country'] === 'field_display_country' && isset($cck_address['country']) && $cck_address['country'] != '') {
            $output .= ' '. $cck_address['country'];
          }
          break;
        case 'other':
          if ($field['fielddisplay']['field_display_other'] !== 0 && isset($cck_address['other']) && $cck_address['other'] != '') {
            if ($order > 1) {
              $output .= '<br />'. $cck_address['other'] .'<br />';
            }
            else {
              $output .= $cck_address['other'] .'<br />';
            }
          }
          break;
      }
    }
    $output .= '<br /><br />';
  }
  return $output;
} // function theme_cck_address()

If this checks out for you, I'll roll a new version.

Okay, my tests allow me to turn off everything a at least with the field not required at all, I was able to show only Address, City, ZIP, and Suite with no submission problems. Hopefully you find the same results. I'm off to check a couple of other combos.

Note, the above solution does not prevent the country and state from being stored, it uses the defaults. So make sure in your case that you set them.

Setting the overall required-ness for the field works; only the fields marked as visible become required for real and the submission works fine.

Did you save all cck fields again per my upgrade instructions?

If so, then yes, it should be another issue. Don't worry about making a patch. Now that you've tested this, I'll just do another release. But just to make sure your error IS a separate issue, please do the following for me...

Download and install the 'devel' module. Activate the 'backtrace' feature. You shouldn't have to activate anything else. Make sure your error reporting (standard Drupal feature) is set to screen and log, not just log. Then visit the offending page. You should get a reverse order list of function calls that made the error, including line numbers and arguments. Either copy the whole thing and post it here, or find the function and line from my module that is causing it and just give me that and the arguments. Then we'll decide whether it's another issue or not.