Same problem here. What is strange is, if i copy the cache from the source to the server, it works. When i do a smarty clean and clear all the files (except index.php)in cache/smarty/compile and cache/smarty/cache, then it goes wrong.
In the past i added an extra field in the order class. This is gone now but somehow it still shows up in the order. The ps_orders table does not have this field, so insert fails resulting in the above message