It’s quite possible in your initial adjustments of the stat, and from memory especially the dead band, you damaged it. I don’t have time to read all the posts, but that’s what I remember.
bradliew I wonder if it just means that the switch was already broken somehow due to some wear and tear?
Mainly the over adjustments I believe you initially made, apologies if you didn’t but it’s become rather a long post to sift through?