I just had an activation issue during my 15 x $200 Everywhere purchase today. 4 of the cards were recognized as unactivated right away by the register and refunded by the register and the Manager kept those cards. Of the remaining 11 cards, 6 of the cards activated fine, and 5 of them were unactivated. So looks like I will have to play this stupid game of getting it fixed yet again. Sure wish they could fix their activation system or make the refund process easier. Perhaps it has since I last did this a few months ago, we will soon see.
One thing that is different now vs a few months ago is that previously the refund would spit right out immediately during the activation process. Whereas now it seems like a popup appears on their register to call a manager over to take care of the issue, and he checks and keeps the unactivated cards, then types in some sort of approval. I wish they would simply refund the entire purchase and cxl the cards that had already been activated (if that's possible), then re-start the entire transaction. That would save a TON of hassle for everybody involved right from the start.