The "non-existent key in manager" error usually refers to a block (icon) in the layout for which the underlying model is not present in the current block library.
This may happen because:
[list]
[li]"a" library is found at the expected location (with the expected name) but does not contain that particular model; or[/li]
[li]the original block library (or instance) was changed, e.g. via the Project / Block Library Setup menu - and the new one does not contain that particular model[/li]
[/list]
This may explain why the original project - that used to work fine, does no longer work.
On the other hand, if a block that is used in the scope of e.g. objectives, calculator variables, etc. is deleted from the layout, this same error message will be displayed.