I have had pressurestat problems on two levers I have owned. The first was in my Elektra MCaL. I turned the machine on, went to take a shower, and then went back into the kitchen to eat breakfast. Shortly after sitting down I noticed a really weird sound coming from the MCaL, so I walked up to assess the situation. When I went over to look at the machine I could not help but notice the pressure gauge was maxed out. After seeing this I quickly turned the machine off. While, for those of you who have never played with an Elektra MCal, they do not have a pressure release on the boiler. So, I was essentially eating my breakfast next to a pipe bomb waiting to explode.
Anyway, pressurestat inconsistency was in this case, and is commonly, caused by a teeny tiny speck of scale getting into the pressurestat itself. Depending on your exact pressurestat, you may be able to take it apart and break it down more than others. You might want to try this and see if you find anything in there. I believe the Elektra had a Mater and I ended up using a needle to pry the tiny piece out of it. After doing this it was fine.
How frequently do you descale the PVL? Santo, what kind of machine are you having problems with? If it is a commercial machine, and you end up needing to replace it, go with a Sirai. They are absolute tanks.