Hi @jmulvaney. This is very odd. I have two Square Terminals that I use as customer-facing devices. They are plugged in all night, every night, and have been for years. If this were a hardware design flaw, there would be much more chatter about it here as a hardware design issue would affect lots of folks. But, something you mentioned reminded me of something that happened to me a few years ago.
You didn't mention the operating environment -- restaurant, bar, retail......? A few years ago, I figured out that my employees were just dropping the charging cables anywhere on my counter. They were exposed to condensation from employee beverage cups, spills and such. When those USB cables ends come in contact with water they can "fry" very easily. And, like you said, sometimes flipping the cable works because they don't fry all of it and for charging the entire cable is not used. But that will only work for a while. Also, we had one occasion where the water contact was enough to short out the charging block and can affect the terminal charging port. What I thought was a Terminal problem was really caused by this, instead.
Is that even remotely possible in your situation?
Chip A.
Square Expert & Innovator and member of the Square Champions group. (But NOT a Square employee, just a seller like you)
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