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I am sorry that you had this problem. It is definitely possible that something in the files produced by the KFX Output plugin triggered this to occur.
I know of two potential problems in sideloading KFX books:
First is that the file size may be larger than e-ink Kindles can safely handle. KFX books produced by Amazon are split up into files of 3MB or less. The KFX Output plugin always creates a single file, and it may be quite large for some books. I have seen KFX files larger than about 16MB lead to the Kindle reader crashing and abruptly returning to the home screen.
Second, loading multiple books on the device with the same ASIN can cause a variety of strange problems. It appears that the Kindle does not properly keep track of them as distinct books.
Yours is the first report I have seen of an unrecoverable problem.
It is odd that you experienced problems with the Vocabulary Builder feature. The KFX Output plugin was changed earlier this year to fix a problem that prevented sideloaded KFX books from working with it and since then I have been able to use Vocabulary Builder with books I converted to KFX without any problems.
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