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If it is a new iron and the drops of water are excessive I would suspect it is faulty.
If the iron is well-used I would suspect it has a scale problem where localised scale build up is preventing some of the water from closely contacting the heated metal and turning to steam. This could be particularly true if you live in a hard water area.
Steam irons originally soon caused problems unless distilled or de-ionised water was used. It is reckoned modern irons can use tap water but hard water can still cause trouble.
A descaler additive might help but I haven't had good results in the past...
Normally when water is put inside steam irons, it get stored in tank then if thermostat knob is set for steam then water moves to bottom heated portion of iron. Water converts to steam as base plate is hot, heated steam comes out through perforated holes. If holes are blocked due to scale formation steam flow is blocked. The descaling has to be done as per instructions given on descaling wax manufacturer. sometimes if water does not enter through a rubber washer that is water tank to heated bottom portion then also steam will not get generated hence no steam. Please check above points and identify the problem.
You have to take part the iron by unscrewing the three bolts on the side handle with a small phillips driver. Then loose the allen screw on one side of the black thermostat wheel to unloosen it. Then take out the two bolt plastic protectors under the handle and unscrew the two allen bolts, carefully separate the top from the botton of the iron, carefully not to pry loose the cables from the top to the hot shoe.
On the back you will see a small white square box, that is the thermostat, which has a button on top, all you need to do is to push it in. This will make the iron heat up unless you have a thermostat failure (Black wheel with temperature indicators), which you will need to order the part and change it.
1:Clean your steam iron according to the manufacturer's instructions. Your
iron is more likely to leak when it has not been cleaned properly.
Plus, the water that leaks from a steam iron that hasn't been cleaned
will likely be dirty and stain your fabric. Every steam iron brand is
different, so be sure to check the manual that came with your iron or
browse the manufacturer's website for instructions on keeping your steam
iron in good working order.
2:Use your steam iron on a rigid surface like an ironing board. In a rush,
you might be tempted to quickly iron a blouse or pants on the nearest
available surface like a bed, carpet or even on a table with a towel
draped over it. However, these surfaces may not provide the proper
amount of level padding for successful steam ironing, and leaks are more
likely to occur. Take the time to set up your ironing board for smooth
steam ironing to reduce water leaks on a bumpy surface.
3:Allow your steam iron to heat fully in the upright position before
ironing. Because your steam iron is designed to convert water into steam
that will easily smooth out wrinkles on bulky fabrics, you can avoid
leaks by ensuring your iron has time to get the water to the correct
temperature. If you lay your steam iron in the horizontal position too
quickly, water that is not hot enough to convert to steam will leak.
Give the iron a chance to heat up, and then test your steam function on
your ironing board cover or spare fabric swatch before tacking your
favorite blouse.
4:Turn off the steam function on your iron when ironing at lower
temperatures. Since your iron's steam function is designed to convert
the water in your iron to steam at the right temperature, lower iron
temperatures can cause water to leak if your steam setting is still
activated. For ironing more delicate fabrics, turn off the steam to
avoid water leaks.
It probably has a high temp overload opened up inside or the thermostat control has gone bad.You can only tell for sure by taking the unit apart and testing the circuit for continuity.The steam feature on the iron is heated by the same element that heats the iron so it wont work.the element itself could also be bad,but I have never seen one go bad.You will have to check each component seperately to find the damaged part.or you can test the whole circuit at the plugs end,and use a jumper across each part until you have continuity through the unit.Make sure the thermostat is turned all the way up.the part that you are bypassing when you get continuity is the bad part. You can buy a cheap continuity checker at any lowes,or even wallmart for that matter.
The screws holding the unit together are T-20 TORX screws; the center post makes them anti-tamper TORX screws. These screws are used in applications in which the manufacturer does not want the average consumer to attempt repairs. Please don't take this wrong, but if you have to ask about the "unusual 6-sided screw", then you shouldn't be opening the unit.
Unfortunately, when the heating element rocker switch gives out (3-4 years), it is usually about time to overhaul the entire iron (both the tank portion as well as the iron portion). Other things that can cause problems are the thermostat and the pressure actuator.
Contact A2A Consulting at 1-888-830-3563; they can probably fix the unit for you.
It appears that your rocker switch is broken, I am attempting to find a source for the switch and the screw driver that removes the screws holding the unit together
I suspect that by placing it on its heel rest the water from the tank is not allowed to enter into the steam chamber and when you go into ironing mode there is a rush of water that is cooling down the sole plate to below steaming temperature. Try keeping it in the horizontal position on a heat proof pad and press the steam button just before going into ironing mode.
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