Sir Secret Agent # R791945 . . . . .
When I initially saw your post I suspected a fault that was not being associated with your thermal sensing /switching/ thermostat unit.
That was being, your use of common tap water in the unit, which could lead up to your potential and probable situation now.
If you have an accumulated lime scale build up between the very center therrmal face of the thermostat it is then not PRODUCING a TRUE sampling of the thermal source.
BECAUSE you then have a thermally insulative layer between the two surfaces . . . the limescale !
Initially . . . get the whole sampling face surface of the thermostat free of all scale, be that by your gradual acidic chemical erosion or merely by a slow controlled abrading it off into dust, with a single edge razor blade or Exacto knife's blade.
THEN, in order to test, you boil water and get two test leads that get clipped onto the 2 contacts of the thermostat. The other cliip leads get connected to a DVM placed in its low ohm scale to see if there is continuity of the thermostat, or an open circit.
( Another option is to use the DIODE / continuity test and its possible continual beep . . . if it doesn't eventually drive you crazy . . . in the case of a closed circuit. )
Then you dip the thermostat into the boiling water, to see that if at some point that the thermostats switching action changes to its opposite.
Then you take out of the water and expect transition on cool down state.
If the max temp of the boiling water is inadequate, then you would have to use the inside of an oven to gradually ramp up the temp to reach higher temps to test.
Then it seems that you might have yourself a properly working unit again.
If this proves to be true, then you put a thin layer of silicone grease*** on both the heated metal area of contact to the thermostat and the face of the thermostat and reinstall the unit and give the whole system a testing.
Then . . . . . see if your heating problems are solved.
***John Q. Public can find his silicone grease guised as "Plumbers silicone grease" at the hardware store.
. . . Or chemists find it available to themselves as glass stop cock grease
. . . Or hot rodder find it as silicone oil . . . . racers HI TEMP brake fluid . . . . (resplendently colored / tinted at . . . . .no extra charge ! )
An additonal HINT . . . . for the future . . . . distilled water is FREE . . . . if you merely think ahead and collect rainwater for its later use in the unit .
If this is being a critical piece of equipment to your livelihood, contact me for a further technique to extend its life.
73's de Edd