Form error in reusable workflow

Hi all
I have taken a copy of the 'Approval - SharePoint 2010' workflow, and plan to customise it as a reusable list workflow.  After publishing the workflow, and adding it to a list in my site, i am trying to start the workflow with an approver and recieve
the following error:
It seems that the error is related to the Approvers field as it disappears when the error pops up.  I've noticed that if the Approvers field is left blank, then the form submits without error (i would expect the opposite to be happening).  I've
also tested the 'Approval - SharePoint 2010' workflow on my list and this works fine.
The form and workflow have not been customised in any way at this point.
The error log reports:
07/17/2012 09:55:26.42  w3wp.exe (0x2A58)                        0x3878 InfoPath Forms Services       
Runtime - Business Logic       82g1 Critical There was a form postback error. (User: ****************, Form Name: Template, IP: , Request: *********************/_layouts/IniWrkflIP.aspx?List={d316b0ca-6659-46ea-86cb-db02f047704f}&ID=24&TemplateID={3983d8f1-b720-4175-bda7-d9bd74341446}&Source=*************/Lists/ChangeList/AllItems.aspx,
Form ID: urn:schemas-microsoft-com:office:infopath:workflowInitAssoc:-AutoGen-2012-07-17T08:51:21:140Z, Type: SchemaValidationException, Exception Message: Schema validation found non-datatype errors.) ac07586b-01da-4fcc-bc30-be11fd21964d
Can someone shed any light on this?
Thanks
Asher
Fast, Cheap, Good. Choose any Two!

Just so we are on the same page, I followed what you did exactly. I created a new site collection and root web using the (Team Site Template). I took a copy of the "Approval - SharePoint 2010" Workflow using a machine with the KB2553322 Patch. It created
a Reusable Workflow called "Workflow 1". I attached it to the default Documents Library. And, as expected, I encountered the same issue. "The form cannot be submitted because of an error."
I then opened the Workflow in the Virtual Machine I created to test this patch (After installing InfoPath I had to remove the update again even though it was still a pending update). Turns out there are 2 updates under KB2553322 one for Office Professional
Plus and one for SharePoint Designer, you need to remove both.
To verify that it is the same problem. In SharePoint Designer, open the site, go to All Files, Workflows, the Name of the Workflow ("Workflow 1" for me) and Open WorkflowName.xoml.wfconfig.xml, then click Edit. Now, in the XML Path, WorkflowConfig ->
Initiation-> DefaultData -> dfs:myFields -> dfs:dataFields -> d:SharePointListItem_RW, the node will look like
<d:Approvers>
<d:Assignment>
<d:Assignee xsi:nil="true"/>
<d:Stage xsi:nil="true"/>
<d:AssignmentType>Serial</d:AssignmentType>
</d:Assignment>
</d:Approvers>
When it should look like:
<d:Approvers>
<d:Assignment>
<d:Assignee/>
<d:Stage xsi:nil="true"/>
<d:AssignmentType>Serial</d:AssignmentType>
</d:Assignment>
</d:Approvers>
So, how do you fix it? and also without SharePoint yelling at you. I also tried just publishing both workflow and InfoPath form with no success.
Open the Workflow in SharePoint Designer
In the Ribbon click Initiation Form Parameters
Click OK without changing anything
Republish the workflow, It will warn you that the infopath form has been customized.
Open the Form that says needs update, it will prompt you that the workflow has changed and InfoPath will update the form.
Save and Publish the Form
Publish the Workflow, again
After that, if you check the .xoml.wfconfig.xml file, it will be updated to the proper version. If you run the workflow in SharePoint, it will still have any customization you had before, with the added bonus that it will work.

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