Acrobat 9 Form Issues - Font, URL, and Print Issues

Hello folks,
We are developing an Acrobat PDF (I have Pro updated to 9.4.5) with about 30 fields. Some of them contain a default label name, others are blank, and all fields have a unique name. The blank fields on the form are being filled via an automated web services API from Aspose. All info is entered and the PDF is then flattened by the web service.
The document fully populates with all expected data but we are running into three issues:
1) A field that gets populated with a URL by the script properly becomes clickable if the font is set to Helvetica, but when set to Verdana or Arial fails to be recognized by Acrobat.
2) When I create a new form field, and assign a font face/size/color and input a default value, if I go back and try and change the size the default content seems to hold it's original size unless I do a full cut/paste of the value back into the box.
3) We are getting the notorious "An Error exists on this page. Acrobat may not display the page correctly. Please contact the person who created the PDF document to correct the problem"
The odd part is we were not getting that error at first - even with data populated. It was only once we started working on getting the fields horizontally and vertically aligned that the error presented itself.
Any thoughts? I have closed and opened Acrobat, tried opening from Acrobat instead of double clicking the PDF but nothing seems to help.

thanks Mylenium
the font association problem is something recent though, since I used acrobat to print mails directly from my gmail account previously...
it's galling but I installed a free pdf printer which does the job, I needed copies of these mails urgently !
as to the update issue, I see no aum.exe, msiexec.exe or setup.exe running... but that's quite above my head... do I look for those exact processes or are they generic names for processes ?
does my question make sense ????

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======================================================
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ID="">
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lookAndFeel="Generic"
colorScheme="teal"
serverApp="default"
logo="no"
imageBase="CodeBase"
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heartBeat=""
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legacy_lifecycle="false"
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Terms,conditions, caveats and small print.<br>
Copyright © 2003 Citigroup. All rights reserved. Unpublished.</font>
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======================================================
forms.conf
====================================================
# Name
# forms.conf - Forms component Apache directives configuration file.
# Purpose
# It should include the weblogic managed server (routing) directives for
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# Forms component OHS directives.
# Remarks
# This file is included with the OHS configuration under
# $OI/config/OHS/<OHS Node Name>/moduleconf sub-directory.
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====================================================
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Hi Michael,
Thanks for your valuable inputs.
Below line in CRMS_KR.htm was causing the problem because while directly hitting the CRMS_KR.htm we had hard-coded all the tag values which in other case is read from formweb.cfg
Before:
*<PARAM NAME="serverURL" VALUE="/forms/lservlet?ifcfs=/forms/frmservlet?acceptLanguage=en-us">*
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