Boulters C2 Pathfinder.. Combustion

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Hi. Servicing an old Boulters C2 /9or 8 pathfinder. The plate on the side suggest original set up for gas oil . The sticker on the burner suggest the same but has since been written over on pen 28sec.. Burner is an old Riello R40 G10. Written on the burner sticker is 170 psi . nozzle 1.5/60. Comb Head 3. Air 3.8 ..So not sure if that is settings for gas oil or kerosene. If the above settings are Kero would suggest about 1.95 usgallons/h
I have an old Boulters commissioning data sheet so I decided to take it back to that. Boiler has a 7inch flue . I fitted a 2.00 /60deg/ W at 100psi. data sheet does not give any head settings. Data from the Riello R40 G10 online manual suggest 2.5 head setting although @ 8 bar (116psi) . Left it at MI of 100psi . First test not great so adjusted air to 3.3 to get 0-1 smoke and then used analyser but the best I could get was 10.3% C02 and C0 @68ppm if I tried less air to bring Co2 up the Co. ppm would start to climb up to 80'.s..
I then tried to set it up at Riello burner MI for that nozzle which was 8 bar (116psi) combustion head set at 2.5 air about 3.3 but even more smoke..
I then settled back at Boulters settings of 100psi , head setting 2. air about 3.2 which gave me the 10.3Co2 and co 67ppm 02 -6.9 flue temp 265deg.
I feel I am missing something . Seems like Im over airing to keep co2 down...? or am I missing something. ?

I am going back any anyway to finish cleaning . Took a 1/2 bucket and 2 hover bags soot / carbon out the chamber. There is a bit of hard carbon stuck at the back Im wanting to get out.. Thought I might try Expell C to loosen off ..Any experience of this ? Ive used Duel X carbon breaker liquid in the past.
 

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