I have not followed any of the evaporator postings and so far my unit works OK. I don't know what are the problems but here is my $0.02.
The fact that Volvo outsources parts to other suppliers does not make it any less responsible for any defects. Neither poor quality of BMW evaporators (or other makes) gives Volvo any excuse nor the fact that in Europe they fleece customers with one year warranty.
All evaporators are designed to work with condensation and moisture since that is how they remove excess humidity from the outside air. Dust is a fact of life for automotive air supply units and should not be used as an excuse. Water freezing on the evaporators should not create any problems or reduce its life, if you want to test the assumption check your fridge as evaporators there get covered with ice all the time. Icy evaporators may impact compressors and condensers and reduce air flow and cause poor air conditioning unit performance. It is a tough job but they should be able to handle it without problems.
But there are togher jobs out there.
In industrial environment I have cooling colis (evaporators) working 8000 hours per year, covered with acidic condensation all the time, and being blasted once a year with 10,000 psi water blaster. They are copper fins with copper tubes with tin coating. After 11 years in service they are still in good condition and have not yet failed.
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