dont copy and paste that, its useless lol look at your code
Code:
// Begin the session
session_start();
if (isset($_SESSION['captcha_time']))
$HTMLOUT = '';
theres your problem, that if when evaluates to false stops the first definition of HTMLOUT, simply your missing a line of code that should go under that IF in login.php, go to the tbdev svn and either copy and paste the line you need or download a new copy of the file