You need to repost this question as an Immigration matter, that way you will more likely receive input from attorneys who have experience in this specialized field of law. Good luck.
As Mr. Jones indicated, you need to speak to an Immigration Attorney regarding this matter. This area of the law is very specialized and if an attorney does not do these types of cases frequently, you need to move on to one that does. Best of luck!
Call Trial Attorney Dustin RT Sullivan at (910) 508-2200 or visit us at www.sullivansnowlaw.com to find out more.
Fingerprint databases are not globally connected. The fact your husband has a prior order is not surprising. It happens a lot in practice. Your attorney should have filed an FBI rap sheet as well as FOIA requests on behalf of your husband to determine all prior criminal and immigration history. If they didn't know about the prior order, then they would have given a bond.