Yeah, I've been struggling with Bitpay from the beginning. Took months to get my card sent to the right place, they asked for more and more informaiton, some of which I didn't have, and when I finally did get the card, I couldn't actually upload money to it after activating it. As a result, I'm a little salty on bitpay, and not overly surprised you're having trouble.

Hopefully they get it together, but as long as their the big dog with no competition, it'll be drama to get them to move more quickly with improvements.