The small pin length was 7.5mm. I had one of those, and the eDGe would charge fine most of the time, all though I had to jiggle it just a bit to be sure. The proper pin length is 9mm, which fits fully.
The "bit of orange" you're seeing means the battery's below 15%.
It does sound like your battery may be defective (it happens
), or it simply may have "died" early, so if you contact enTourage tech support directly, I'm sure they'll help you out.