Crystal report reverts to SANDBOX mode even though the *.rpt file was not modified

We have a v12 client with a Workflow that runs nightly and emails a PDF attachment. On at least two occasions the first record triggered generated an email without the attachment but the remaining records processed in that same execution of the Workflow with attachments. This error appeared in the Log for that first record (Note: I've replaced a portion of the server name with xxxxxxx):


<0001 Job retrieval error jobrpt_YLISREG_ADMIN_68192 : Status=99 ->Job 1172 - ERR 504 coming from the edition server : Error induced by the print engine Crystal .NET.
YLISREG.rpt - - Message 1/3 : Error running the report: D:\Sage\SafeX3\EDTV2\X3RPT\
23:00:10 Printing Report YLISREG
Print Server : xxxxxxxApp:1890
X3DOS=PROD;xxxxxxxApp;1812;150;ENG

I'm aware of the quirk where after modifying a Crystal *.rpt file the first time you try to print the report within X3 it will fail with a similar error. I can also reproduce the error 504 by making a change to the Crystal *.rpt file. HOWEVER, the Crystal file had not been modified before the execution of the workflow when it failed. The only out of the ordinary occurrence is that we had applied the latest X3 Security patch to the v12 Production folder on the prior day.

Has anyone else seen this behavior with a Workflow triggering the Error 504 without having modified the report it is calling?