KRC2 Automatically Reboots After Shutdown — Can’t Prevent Restart

    • New

    Hi all,

    I’m working with a KUKA KRC2 robot running Windows XP, and I’m trying to configure it so that when I issue a shutdown from the KCP, the system stays powered off. Currently, every time I shut it down (using the KCP or Windows), the controller powers back on automatically within a few seconds.

    Here’s what I’ve tried so far:

    • Checked the BIOS for “Power On After Power Loss” or auto-boot settings — nothing relevant found.
    • Used the ColdStart.reg file from C:\KRC\UTIL\REGISTRY\, but the CCU\Startup key doesn't exist in the registry.
    • Manually created the missing registry path:
      HKEY_LOCAL_MACHINE\SOFTWARE\KUKA Roboter GmbH\CCU\Startup
      and added ReStartType=0 as a DWORD (hex) value.
    • Enabled “Cold Start” and “Disable Power Off Delay” in the KUKA HMI On/Off Options.

    Despite all of that, the robot still reboots automatically after shutdown unless I physically turn the cabinet key switch to OFF (0). Ideally, I’d like to be able to shut it down remotely or at least via software only.

    Has anyone successfully solved this behavior on an older KRC2 (non-ed05) system? Is there a hardware jumper or relay I’m missing that causes the PC to repower?

    KPC ed05

    KRC2

    KCP2

    KSS 5.5.12

    Thanks in advance for any insight!

  • SkyeFire May 9, 2025 at 7:31 PM

    Approved the thread.
    • New

    Thanks for the reply!

    Yes, to clarify — right now our shutdown process is:

    1. Press the KCP “Shutdown” softkey (not the Windows Start Menu).
    2. Wait for Windows XP to fully shut down (black screen, no drive activity).
    3. Then we turn the cabinet key switch to OFF (0) to fully cut power.

    If we don’t throw the switch quickly enough after shutdown, the KRC2 logic reboots the PC again, which is what we're trying to avoid — mostly to protect the old mechanical HDDs from power cycling stress.

    We were hoping to configure the system to stay off after shutdown, so we wouldn't need to rely on someone manually throwing the switch every time. But it sounds like, based on what you said, that’s just how KRC2 systems work until at least KSS V7 — the PLC sees the shutdown and re-applies power unless the key is off.

    • New
    Quote from MFab

    Thanks for the reply!

    Yes, to clarify — right now our shutdown process is:

    1. Press the KCP “Shutdown” softkey (not the Windows Start Menu).
    2. Wait for Windows XP to fully shut down (black screen, no drive activity).
    3. Then we turn the cabinet key switch to OFF (0) to fully cut power.

    If we don’t throw the switch quickly enough after shutdown, the KRC2 logic reboots the PC again, which is what we're trying to avoid — mostly to protect the old mechanical HDDs from power cycling stress.

    We were hoping to configure the system to stay off after shutdown, so we wouldn't need to rely on someone manually throwing the switch every time. But it sounds like, based on what you said, that’s just how KRC2 systems work until at least KSS V7 — the PLC sees the shutdown and re-applies power unless the key is off.

    What happens if you just turn the shutdown switch on the controller without selecting shutdown option from the KSS menu? Usually that is the rightway to shutdown KRC2 controller. There is no need to first choosing the shutdown menu option. With shutdown option choosing from the KSS menu, the controller just reboots. If I can remember correctly, it has been always like that.

    Also old mechanical DOM's can be replaced by flash DOM(Disk On Module) or even with SATA by using IDE-SATA adapters. I would recommend to make full HDD clones while system is still in good working condition for later easy restoring on newer disks when old IDE HDD disks will start to fail. It will save you a lot of trouble, time and money.

    • New
    Quote from DannyDJ

    What happens if you just turn the shutdown switch on the controller without selecting shutdown option from the KSS menu? Usually that is the rightway to shutdown KRC2 controller. There is no need to first choosing the shutdown menu option. With shutdown option choosing from the KSS menu, the controller just reboots. If I can remember correctly, it has been always like that.

    When I turn the key switch, the system does shut down — no issues there. I had just assumed that doing it that way (without using the KCP shutdown menu) might be harmful to the mechanical DOMs or IDE HDDs, since it felt like cutting power without giving Windows a chance to close things properly.

    That’s what led me to believe there must be a more “correct” or graceful software-based shutdown method, which is why I came here to ask the great and all-knowing minds of this forum!

    Sounds like maybe I was overthinking it — if the key switch is designed to signal a proper shutdown sequence internally, and Windows handles it cleanly, then I guess that really is the intended way.

    Thanks for the clarification!

    • New
    Quote from MFab

    When I turn the key switch, the system does shut down — no issues there. I had just assumed that doing it that way (without using the KCP shutdown menu) might be harmful to the mechanical DOMs or IDE HDDs, since it felt like cutting power without giving Windows a chance to close things properly.

    If controller switches off immediately indeed there is a danger of damaging system. Thats why there are accus inside the control cabinet floor to buffer shutdown after you turn the power switch. So check if you accus are ok. A immediate shutdown is not normal system behavior.

    • New
    Quote from MFab

    When I turn the key switch, the system does shut down — no issues there. I had just assumed that doing it that way (without using the KCP shutdown menu) might be harmful to the mechanical DOMs or IDE HDDs, since it felt like cutting power without giving Windows a chance to close things properly.

    That’s what led me to believe there must be a more “correct” or graceful software-based shutdown method, which is why I came here to ask the great and all-knowing minds of this forum!

    Sounds like maybe I was overthinking it — if the key switch is designed to signal a proper shutdown sequence internally, and Windows handles it cleanly, then I guess that really is the intended way.

    Thanks for the clarification!

    When you turn the key switch OFF at the controller, system should start slowly shutting down,Windows should start closing like on ordinary Windows Xp desktop PC when you pressed ON/OFF button(logg of the current user, etc,...), if the screen on the kuka pendant goes instantly off, usually then this is sign that your backup batteries need replacement, like the Fubini wrote.

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