'Free shipping' is somewhat of a misnomer. What it actually does is to to exclude the weight or value of the item from total used to calculate shipping, so the shipping price for the order will be the same as it would be if the item was not in the order. To make sure that an order with just a single item that is 'Free shipping' actually gets free shipping, you should ensure that your shipping setup includes a 'zero' band, resulting in a shipping cost of zero for order weight/value up to 0.01 (or 0.001 for example).

For more information on configuring your store's shipping, please see 3.6.5. Shipping / postage.

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