Could it have a faulty memory backup battery (or capacitor if that is what is used) that is no longer storing various volatile settings when the machine in turned off such that they get scrambled? Not everything in the KN6000 is stored in non-volatile flash memory - some settings are lost after a period of inactivity, implying that there must be some sort of power source inside that gradually runs down. The power-on reset procedure obviously sets all volatile settings back to a default state and allows the machine to boot properly. Maybe a trip to a service centre is needed if this is the case.

Richard