Are you definitely setting the parent category as the category you want to expand it under ?
-- Set the name for the Category for the Panel
panel.name = "Profile Manager"
-- the panel.name value of the parent configuration panel, used to display a hierarchical category tree.
-- If the parent panel is not specified or does not exist, the panel is displayed as a top-level panel
panel.parent = "Parent Category Name"
Granted I don't have a triple layer of options yet in my UI addon so unless this is a limitation of Blizzards options panel system it should work in perpetuity (sp).
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