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That happens when a new scene relies on variables that did not even exist in previous releases. When loading from a save, the chapter that initializes the variables (new ones included) is not run, and thus one must start over.

is there any logic to check if variable exists if not set it when sleeping or start a new day or anything?

Nope, nothing like that.

Ive never had to start over. New stuff still works with previous save. Android version