Yeah, in whatever script you call this:
('http://www.mysite.com/threads/chatpopup.php?
Cat=&Username=$Username&Usernumber=$Usernumber',
'chatpopup','width=300,height=250,top=100,left=150,screenX=1,screenY=1,
scrollbars=yes,resizable=yes');</script>
Make sure $Username & $Usernumber has been defined before it. You may need to do
$Username = $user['U_Username'];
$Usernumber = $user['U_Number'];
or something similar to set that up.
Try adding :
echo "Name = $Username <br />";
echo "Number = $Usernumber <br />";
near the top of chat popup to debug it.... see if it has a name and number... if not, that's the problem.