Weil-McLain Ultra Ultra Series 1 Guide

Part Number 550-100-061 1005
The replacement gasket kit (P/N: 383-500-133) includes four equal length pieces of
adhesive backed gasket material. These new gaskets will be applied to the base of the
boiler opposed to the plastic door as done previously.
Installation Instructions:
1. Turn off service switch on boiler control panel.
2. Remove boiler front door by removing the two knurled screws at the bottom with a flat blade screwdriver.
Once the knurled screws are removed, lift the front door off the boiler.
3. Remove the existing gasket and adhesive from the top, bottom, and sides of the front door.
4. Clean the edges of the boiler in the locations of the new gasket as shown in Figure 1. Isopropyl Alcohol
may be used to remove any oil or residue. Allow the surfaces time to dry before continuing to the next step.
STOP! Read before proceeding:
WARNING Turn off gas and electricity before replacing gaskets. If boiler is hot from operation,
allow time to cool before proceeding. Failure to follow all instructions can cause
severe personal injury, death or substantial property damage.
When applying the gasket only remove plastic backing to expose the adhesive as
needed. This will make the gasket easier to handle. Minimize gaps between sections
of gaskets and trim any excess length.
Instructions:
Gasket Replacement
Ultra Series 1 & 2
Gas-fired
water boiler
CAUTION If boiler is hot from operation, allow time to cool before proceeding. Failure to
perform the following can cause minor personal injury or property damage.
NOTICE
Indicates special instructions on installation, operation or maintenance that are
important but not related to personal injury or property damage.
NOTICE
Do not stretch gaskets when applying them to the boiler. Simply press the gasket
firmly into place to allow the adhesive to make contact with the boiler.
NOTICE
WARNING These instructions must only be used by a qualified, installer/service technician.
Read completely before beginning the replacement. Failure to follow all instructions
can cause severe personal injury, death or substantial property damage.

Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
http://www.weil-mclain.com
Part Number 550-100-061 1005
5. Top Gasket - Peel back a small portion of the plastic backing off the gasket to expose the adhesive.
Begin applying the gasket to the top of the boiler as shown in Figure 1. The gasket should be applied
around the perimeter of the control pod.
6. Side Gaskets - Peel back a small portion of the plastic backing off the gasket to expose the adhesive.
Begin applying the gasket to the top of the boiler adjacent to the top gasket as shown in Figure 1.
Apply the gasket around the corner and down the length of the boiler. Repeat application for
remaining side.
7. Bottom Gasket - Peel back a small portion of the plastic backing off the gasket to expose the
adhesive. Begin applying the gasket adjacent to the side gasket as shown in Figure 1. The gasket
should be one inch below the top of the sheet metal base pan. Apply the gasket along the front of the
boiler until it reaches the other side gasket. Trim the gasket to length to minimize the gaps between
the gaskets.
8. Reinstall the door and secure it by tightening the two knurled screws. Restore the electrical and gas
supplies to the boiler.
9. Restore the boiler to normal operation.
FIGURE 1