140W and 30ml isn't pushing the boards. They can handle over 200W but battery safety makes 200W the practical limit. I have no way to know if your iron was the common denominator but it is something almost always overlooked. ESD parts damage shows up in unexpected places often with odd symptoms. A part can be weakened but still function, and then fail under long term stress or just fail unexpectedly for no apparent reason. Again, I have no way to know if that's what's causing your failures, but four dead boards would lead me to look for a common denominator in my shop. A cheapo soldering iron that's not ESD safe would be first on the list of things to never use again. The one you linked says it's ESD safe and has good reviews, so hopefully it lives up to its description. [/QUOTE] Thanks for the input. I'll keep this thread updated.