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This functionality is a post LabVIEW 8.0 feature. The original config file VIs originate from way before that. They were redesigned to use queues instead of LVGOOP objects, but things that were supposedly working were not all changed. Also using the "create or replace" open mode on the Open File node has the same effect. Still something else is going on here too. The Config file VIs do properly close the file which is equivalent to flushing the file to disk (safe of some temporary Windows caching). Unless you save this configuration over and over again it would be VERY strange if the small window that such caching could offer for corruption, would always happen at exactly the moment the system power is failing. Something in this applications code is happening that has not yet been reported by the OP.