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You are using a stale refresh token. Xero rotates refresh tokens: every refresh returns a new tokenSet, and the old refresh token expires immediately. If you keep refreshing with the refresh token from the original tokenSet instead of the newest one, Xero treats the replayed token as a violation and disconnects the app, after which only manual reauthorization works — which is why your reconnects only fix it temporarily. The fix, confirmed by the maintainer: after every refresh, persist the new tokenSet (the new refresh_token) and use that for the next refresh. Also watch out for concurrent long-running processes each caching a refresh token at startup and both trying to refresh — the loser replays an expired token and disconnects the app. One process, one persisted latest tokenSet.
Source: https://github.com/XeroAPI/xero-node/issues/382
Source: https://github.com/XeroAPI/xero-node/issues/382