I went brave enough, tried D drive KRC setup.
I was able to wipe clean and restart the system.
Then I copied KOPs and application programming from archive file.
So far so good. Now I'm looking for work visual program upgrade as well as software upgrade.
I see there some error messages regarding safety circuits but I think I can manage.
Thanks all for assist me to correct path.
The current system vision uses Omron with Halcon software.
The product with O-ring is not same size every parts, so OEM made complicated(?) visual C++ programming for part image tolerances for precision robot pick positions. This was the major problems for us. Now, with Keyence IV-500 series camera sensors, it only detect its presence and don't care for part sizes.