Unable to plot to PDF via Print Organizer (Sheet Index) in ORD Connect if .dgn contains a reference

When we (multiple users) plot to PDF from any project in our Active Projects directory (in PW .453) , we get these errors. We're using ORD Connect 10.10.01.03. We are using the Sheet Set feature. Once Print Organizer runs, the PDF produced contains ONLY plots of .dgns that do NOT contain a reference .dgn. For example, the cover sheet will plot, summary tables will plot, etc - but a P&P sheet will not, Drainage Area Map will not, etc.

"unable to load design file..."
"unable to collect state information from..."
"Exception encountered inside [WorkerMicroStationProxy.Get.Design.State]"

Further, if I go to File > Print > Plot to PDF, I can plot each individual sheet, one at a time (opening each .dgn one at a time) with no errors.
Further, this error only happens in our Active Project directory, and not our Test Project directory (where I developed our custom config).
Further, if I attempt to create a new .pset outside of the Sheet Index - the behavior is basically the same - only .dgns with NO references will load into the .pset. Dgns with references will not be added to the .pset. The same errors as pictured above will occur.

I first submitted a SR to Bentley on 4/14.

We are desperate for a solution.
Any suggestions are appreciated.