Several weeks back there was a post on this, and I had mentioned I believe my problem with black mold on the hi dense foam duct on my window unit. I did as you, thoroughly cleaned the entire unit and and it took most of a hot sunday afternoon about a year ago. It was a bit of a task to get in all the areas to clean, my evaporator was coated with a felt of dust or fuzz etc. I did not have that thickness of black mold, but it was becoming very noticeable, even on the louver directing cold air out.
The rest of this house has central A/C, one area has the window unit, most run about the same time when hot, but I used to cool off that area and shut it off, bad move, condensate did not evaporate, hot and humid nights, perfect for mold. So now I just let it run thermostatically, fan can't be much power, has to be the compressor. This seems to evaporate the condensate, air flow, cold or just fan, alternating, went all last year after that cleaning and so far this year a little given the rainy weather, no sign of any black mold.
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