1.how can the same sub-proc be called second-time with cases from the firstcall still pending in it?

ANS:--Any task (User, Service, Sub-proc call) cannot be instantiated more

than once concurrently; once it has completed you can invoke it again, but
not while it is still live.
You have 2 solutions, both involve fairly advanced iProcess knowledge:
1) Use a Graft step. You can graft extra sub-procs onto a live graft step; but
you need to write code to do this - graft steps are invoked via code "external"
to iProcess. This is generally covered in the iProcess training course.
2) Use a dynamic sub-proc call (which is what you are probably doing at the
moment), and use an iProcess Event step (a Business Studio Receive Task) to
receive the request. You can use a "special" data construct in the "abox"
data, to force the event call to propagate data down into a sub-proc instance
(use the $IPTx format); if that instance does not exist as a live sub-proc
instance, then the BG will creat that instance and add it to the dynamic subproc call. This is not usually covered in the iProcess training course.
Option 2 requires a very good knowledge of iProcess, and I only know of one
or two sites that have used it. You cannot add the instance by just looping
your process back onto the same call - it has to be via the Event call.
There are other threads dated from a year or two ago covering this in more
detail on either this discussion or the BPM discussion.