If you are upgrading to a larger channel NVR, why not just keep the old NVR until the video ages out? You aren't reusing the drives because you would need to buy new drives to clone the data to, so just put new drives in the new NVR, correct?
As Matthew mentioned, DVR Examiner could work, and in terms of customer cost, how much would they be paying for the time/effort/storage to backup 16TB of video?
I have not tried cloning NVR drives, but I would imagine just making sure the format of the new drive is correct, there should be no issue. I would be concerned about how the data was written to each drive, and if drive naming and sequencing could be critical? These are just general guesses/concerns.
I have backed up well over 16TB of storage, but it was a purposely designed plugin within a VMS and Veracity Cold Storage device, and not applicable in this case. It sounds odd to me that even trying to back up hours of video, results in failure? I wonder if there is a backup transfer size limit that isn't documented?