Did you take a look at these two logs?
SAS-configuration-directory/Lev1/Web/Logs/SASServer1_1/SASVisualAnalyticsHyperlink7.x.log
SAS-configuration-directory/Lev1/Web/Logs/SASServer1_1/SASVisualAnalyticsTransport7.x.log
When the PDF failure occurs, do all recipients get the failure email, or just the 3 - 5 users you add.
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