i always set my thermostat at the 3/4 level ngayong tag-init. fan lang ang nilalakasan ko pag bagong andar. the thermostat only regulates the time the compressor turns on or off. the coolness of the air is constant whether it is turn to full or halfway (wag lang sa minimum). the sensor na nakatutuk sa evaporator coils senses the temperature of the coil (not the cabin). kinda like a refrigerator.
I had the same problem, i had it claened, mabango nung una then later on bumalik again. I discovered na yun carpet ko was wet dun nangagaling yun odor, the fins of the Condenser doesn't have any smell kaya dapat la odor ang aircon mo lalo na at bnew pa unit mo, check the drainage nun aircon mo from the inside bka barado kaya nag ooverflow sa loob and bumabaho... just a guess. Pero better have it chk sa casa for warranty purposes....