I agree, Bernie. Many things could cause a backup failure. John gave one example. Any power failure during the process could cause it. But if we keep a copy of the private folder of the SD somewhere else, like the PC, we can always recover from that copy.
I don't use the backup process with the SD Explorer at all. I copy the Private folder of the SD card to the PC. Then if I want a second (or new) copy of the SD, I format the new SD card at the KN7000 and save a file (anything will do) to create the file structure. Then I move the SD card to the PC and copy the CONTENTS of the Private folder in the PC to the Private folder of the SD card, overwriting the file I had saved to create the file structure. That makes an exact duplicate of the original card.
One nice aspect of the SD Explorer backup and restore process though, is the ability to send files, including their long song names, to someone who also has the SD Explorer in their PC. You can't do that with a floppy disk. So, if you have some stuff you want to send to someone, you can save it to a SD card, do a backup, and then send the backup. The recipient can then restore to a blank SD card and they have the files with their long song names. Joan Banfield taught me that.