I have a somewhat similar issue with my Harmony 628, but I think it's more my Comcast/Motorola DVR's fault. When I shut everything off, the DVR sometimes just decides to refuse that command and stays on. Then when I go to turn everything back on, the DVR decides to turn off. This totally screws with the Harmony, and unfortunately makes it almost worthless since it's a hassle to individually turn on the components. I blame comcast.