Almost Heaven Saunas Barrel Sauna Operating instructions

Barrel Sauna
Canopy Barrel Sauna
Installation &
Owner’s Manual
Revised April 20, 2009

TABLE OF CONTENTS
Parts List .......................................................................................................................... 3
Dealer Information ............................................................................................................ 3
Check your Boxes ............................................................................................................ 4
Electrical Requirements .................................................................................................... 4
Locating the auna .......................................................................................................... 4
Basic Tools ....................................................................................................................... 4
First Considerations........................................................................................................... 5
Room Assembly ............................................................................................................... 5
Band Assembly ................................................................................................................ 7
Door Handle ..................................................................................................................... 7
eats & Trim ..................................................................................................................... 8
Heater ............................................................................................................................... 8
Heater Fence Assembly and Installation ........................................................................... 9
Light .................................................................................................................................. 9
Treating the auna............................................................................................................ 10
Operation .......................................................................................................................... 10
Taking a auna Bath ........................................................................................................ 11
Traditional teps in Taking a auna Bath ........................................................................ 11
Maintaining your auna .................................................................................................... 11
Accessories ...................................................................................................................... 11
Warranty ........................................................................................................................... 12
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Parts List Quantity Per Sauna
Description 6x4 6x6 6x8 Canopy
tandard tave * * * *
Final taves 2 2 2 2
Drain tave 1 1 1 1
Rear Wall 1 1 1 1
Front Wall with Door Assembly 1 1 1 1
Cradle Bases 1 1 1 3
Interior eat et 1 1 1 1
Exterior eat et 0 0 0 1
Door Handle et with crews 2 2 2 2
Heater 240V 4.5KW 1 0 0 0
Heater 240V 6.0KW 0 1 0 1
Heater 240V 8.0KW 0 0 1 0
Heater Fence Kit with Nails, crews & Bit 1 1 1 1
Rocks -Carton 1 1 1 1
Light Fixture with Outside Access Plate 1 1 1 1
Thermometer, Chrome 5” 1 1 1 1
Bucket with ladle 1 1 1 1
and timer 1 1 1 1
Towel hook 1 1 1 1
Magazine rack 1 1 1 1
Interior eat upports 0 2 2 2
Exterior eat upports 0 0 0 2
Exterior eat wall mounts 0 0 0 2
Barrel auna Installation and Owner’s Manual 1 1 1 1
Hardware
12ga. X 2” tainless teel Finishing Nails 100 100 100 100
2” stainless steel square drive screws 0 0 0 12
Heater Hardware (Included with kit) 1 1 1 1
Light Hardware (Included with kit) 1 1 1 1
tainless teel Bands 2 3 3 4
tainless teel Banding Brackets 4 6 6 8
Black Vinyl Thread Protectors 4 6 6 8
1/2” x 4-3/4” Threaded Rod 2 3 3 4
Nuts 1-2” x 13 4 6 6 quare Drive
crewdriver Bit
Wood Glue
* Check Packing List for quantity furnished.
Please fill in the following information. It will be very helpful should you ever have questions or
concerns regarding your sauna.
Model: ___________________________________________
erial Number: ____________________________________
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Rea this entire manual through to the en before procee ing with the assembly.
CHECK YOUR BOXES
Be sure to immediately check your boxes against your shipping list and bill of lading. Examine for any damage and report it to
the shipping company immediately. Notify us if there needs to be a repair or replacement of damaged or missing materials.
ELECTRICAL REQUIREMENTS
All electrical wiring must be performed by A QUALIFIED LICENSED ELECTRICIAN. Please do not attempt to do the hook-up
by yourself. Because of the heat involved in the sauna, it is required that you use copper wire with 90ºC insulation. Do not use
aluminum wire to make the connection. Consult with an electrician so you can determine the requirements for your particular
situation. All wiring must conform to all national, state and local codes and regulations.
LOCATING THE SAUNA
Because the customary sauna experience involves a heating-cooling-resting process, it is important to plan ahead before
installing yours. Our method of construction affords the widest number of possible choices because our Barrel auna room can
be placed in either an indoor or outdoor setting.
You will probably shower during or after each sauna bath, so consider having a shower stall nearby. You can place the sauna
in your backyard, especially if you have a hot tub or swimming pool there. If your setting is rural, locating near a pond or
stream is ideal.
Besides the shower, you may want to have a lounging area set aside for relaxing after your sauna bath. Make sure the floor or
ground is level and can support the weight of the sauna (which can exceed 1,000 lbs. when filled with people). A reinforced
concrete pad is always best for outdoor installations.
Verify that both the inlet and outlet vents will remain unobstructed. For indoor installations be sure that both vents open into the
same room or space.
BASIC TOOLS
You should have the following tools:
* Wrench-adjustable, box, open end (10mm, 3/4", 1/2” and 7/16”) * Nail et
* Rubber Mallet * Pencil
* andpaper – 120 Grit * Utility
knife
* crewdrivers (Phillips and Flathead) * Level
* Framing quare * 3/16” drill bit (Canopy Barrel only)
* 5/16” drill bit (Canopy Barrel only)
When building this sauna, you will need to have an understanding on the terms plumb, level and square. These terms are
more difficult to explain than to apply, but it is critical that the unit is installed square and on a level surface.
* quare - Two perpendicular lines are square when they form a 90° angle with one another.
* Plumb - If you hang a weight on a string, the string will hang perpendicular to the horizon, representing the pull of the earth’s
gravity. The line of the string is plumb.
* Level - When you stand on the beach and look out to sea, the horizon looks more or less like a straight line. That line, and
any line parallel to it, is level. A line is level when it is square to a line that is plumb.
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To help speed up the installation, substitute a deep well socket wrench for the ¾” wrench and a reversible
power drill for the screwdrivers.
FIRST CONSIDERATIONS
When you begin the initial layout for assembly, it is very important to check your floor or deck to see if it is level. Most
garage floors, basement floors, and decks are sloped for drainage. If this is the case in your installation, you must use
shims to make the sauna level. Failure to do this will result in unplumbed panels, poor fit and or poor function of your
sauna.
OUTDOOR INSTALLATION RECOMMENDATIONS
• Take caution to prevent the wind from catching and breaking the glass door.
• Do not install boards with knots on the top of the sauna where water could accumulate and freeze, causing the
board to split.
ROOM ASSEMBLY
Before beginning the assembly, unpack all of the staves and identify the drain stave, which will be the first one used. It
has a hole cut into its center. As you examine the staves, you will notice that each end has a croze on its inside face.
The croze is the square cut groove into which the sauna end panels fit. (See Figure 1)
Begin the assembly by placing the cradle bases on the floor or foundation. (See Figure 1). If it is an exterior installation,
anchor bolts should be used to secure the structure against wind damage.
Place a cradle base at each end of the sauna so that it is 4 inches in from the end of the stave. This will facilitate
placement of the end hoops. For the 8’ models the third cradle section should be placed in the center (do not block the
drain hole). Be sure the cradle bases are parallel to each other.
Place the drain stave exactly in the center of the cradle base to provide good drainage. Lay out additional staves on
each side of the drain stave to each end of the cradle base. Using a framing square, make sure that all the staves
are square to the cra le an that the croze is line up on all pieces. Nail the bottom staves to the base with 2½ inch
stainless steel nails as shown in Figure 1.
At this point, uncrate the ends and place them in the croze on each end of the assembly (See Figure 1). Make sure that
the joints on the end assemblies are perfectly vertical, and that the horizontal brace boards are to the inside of the
sauna. Using your level, check the horizontal boards on the insides of both ends to be sure that you have the panels
plumb. The vent hole (with cork) is to be on the BOTTOM on the back (heater) end, and at the TOP on the door end of
the sauna.
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Note for Canopy Barrel:
The croze cut-out for the front wall section on the Canopy Barrel is located 24” back from the front edge of the
sauna.

Work from one side and
start placing the staves
on the ends. Nail the
staves (from the
outside) below the
middle of the sauna to
hold them in place until
the hoops are placed.
Be very careful to
keep the staves tight
against each other.
Use a mallet if
necessary. You should
be able to stop nailing
once you have gone
half way up the side.
The fewer nails you use now, the easier it will be if you ever need to dismantle and move the sauna.
When you come to the point of closing the
assembly you will find that the space left
over may not be equal to a whole stave. We
have provided a final stave set cut into
various widths, (See Figure 2). If
necessary, use the correct combination of
pieces to provide the tightest fit. Install by
tilting out the adjacent staves, placing the
final stave, and pushing back into place.
Figure 1—Base Assembly
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Note for Canopy Barrel:
Use the 2” stainless steel square drive screws to at-
tach the staves to the front cradle base on the Can-
opy Barrel. This is because this will be an exposed
area, and the stainless screw heads will provide a
more finished look. Drill a 3/16” hole through the
center of the stave into the cradle, and then drill a
slight countersink with a 5/16” drill bit. crew in the
stainless screws so that the screw head is flush with
the stave. ee figure 1A.
Figure 1A
Countersunk
Stainless Screws
in exterior canopy

BAND ASSEMBLY
Each of the Band Assemblies are made of the following components:
(1) tainless teel Bands
(2) tainless teel Banding Brackets
(2) 1/2” Nuts
(2) Black vinyl caps
(1) 4-3/4” Threaded Rod
Place bands with pre-assembled brackets around sauna, spaced evenly apart. Insert threaded rod through the
bracket. Install nuts evenly. Before tightening nuts, check to make sure bands are still even. Tighten nuts and
install black vinyl thread protectors. (See Figure 3)
Figure 3 - Ban Assembly
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DOOR HANDLE/TOWEL BAR
The door handle/towel bar assembly will consist of the following components:
(2) Door handles (1) Binding nut
(2) hort round spacers (1) Long machine screw
(2) Long round spacers (2) Wood screws
Locate the single hole in the glass door. Push the long machine screw through one of the pre-drilled handles,
through a long round spacer, through the glass, through another long round spacer and then through the other pre-
drilled handle. Turn the long machine screw into the binding nut but don’t fully tighten. With a level, position each
of the handles so that they are horizontal and then screw the end of the handles into the hinge board that is at-
tached to the glass door with the wood screws. Now tighten the long machine screw into the binding nut. TAKE
CARE THAT YOU DO NOT OVER TIGHTEN THE CREW AND BINDING NUT OR ALLOW THE WOOD
CREW TO HIT THE GLA . BROKEN GLA I NOT COVERED UNDER WARRANTY.
Door Han le Assembly
Door Han le Assembly
Note for Canopy Barrel:
Position one band each around where the two wall sections attach. Place the third band equal distance between
these two bands. Place the fourth band 3” back from the front of the sauna around the exterior sitting area.

HEATER
Mount the heater as shown in the manufacturer's instructions. The heater should be positioned between the seats on the
back wall and no lower than 6-1/2 inches from the floor. The lower the heater is, the hotter the temperature will be at the
benches. All the necessary hardware is supplied with the heater. Do not attempt to wire the heater yourself. Contact a
licensed.
NOTE: Use the two 1/4” x 1-1/4” tainless teel Lags for the top mounting bolts on the heater.
Figure 5 - Seat Installation Center eat upport
Rear End Cleat
Use stainless steel nails
SEATS & TRIM
Each bench consists of 3 slats (See Figure 5). Lay the slats on the lower cleats mounted on each end. pace the slats
evenly and nail them into the cleats. Install center supports (on 6' and 8' models) as shown in illustration. Be sure to set
nail heads below the surface so you will not burn yourself while using sauna.
A small tube of glue has been included in this kit for your convenience. This glue can be used to repair boards that crack
or splinter inadvertently during assembly.
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Note for Canopy Barrel:
Assemble the exterior benches as shown below in the same way you assembled the interior seats and trim. You
will attach an exterior seat wall mount to the sauna wall, using a level to insure that the seat is level.
eat upport
Wall Mount

HEATER FENCE ASSEMBLY AND INSTALLATION
The Heater Fence is necessary to ensure that bathers in the sauna do not accidentally contact parts of the heater that
would burn them. It consists of four precut, vertically notched posts and six horizontal rails that must be assembled
before it is installed to the wall adjacent to the heater.
The vertical fence posts have slots cut into them for the rails. The two vertical fence posts that go against the wall have
slots on just one face, as well as counter-bored screw holes for attaching them to the sauna wall. The two fence posts
that sit away from the wall will have slots cut into two of their faces.
Note the beveled ends on the fence rails that go into the corner posts. The ends of the rails that go into the fence
posts that attach to the wall are square. Assemble the fence before attaching it to the wall by placing the rails into the
slots in the posts and using the supplied 1” nails as shown in Figure 6. You may want to put a small amount of glue
into the slots. Be sure to nail at an angle so that the points will not go through the post. Countersink all nails.
Once the fence is assembled, attach it to the wall behind the heater using the supplied wood screws.
LIGHT
Have a licensed electrician mount and wire the light fixture (on a separate circuit) into the electrical box mounted in the
sauna’s back wall.
Do not install your light switch inside the sauna. No special type of light bulb is required, but the heat of the sauna will
shorten the life of a normal bulb. An appliance bulb, such as those used in a kitchen oven, will last longer than a
standard bulb. Most people prefer subtle, low wattage lighting in the sauna. Do not exceed the wattage
recommended by the light’s manufacturer.
Figure 6 - Heater Fence Assembly
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TREATING THE SAUNA
aunas have traditionally been left untreated to retain the natural look and feel of the wood. Never treat the inside of
the sauna, and treatment of the external of the sauna is optional. If a protectant is desired for the exterior of your
sauna, contact your local paint supply store for a suitable cedar wood treatment for the exterior of your sauna. A sug-
gested treatment to retain the color of the sauna is a 50/50 mixture of linseed oil and rubbing alcohol that can be
rubbed onto the exterior of the sauna. Left untreated, the exterior of an outdoor sauna will eventually become silvery-
gray in color, and it is fine to let the sauna weather naturally if you prefer.
OPERATION
After the sauna has been installed, sweep down the inside to remove any sawdust and wood shavings, and then
vacuum completely. Using a damp cloth and warm water, wipe down the entire sauna including the benches to re-
move any remaining dirt and debris. Rinse off the sauna rocks and install them in the heater. Turn the heater on to the
maximum setting and operate it for about 30 minutes with the door propped open. Then close the door and allow your
sauna to come up to the desired temperature.
If the sauna wood has absorbed moisture in storage, the staves may become loose after the intense heat causes the
wood to cure. It may be necessary to retighten the stainless steel bands periodically if this occurs.
The controls of the sauna heater are mounted at the bottom of the heater. The right dial is the temperature setting and
the left dial is the combined timer on-off switch. Please refer to the manual that came with your heater for full heater
operational instructions
When operating the heater, always begin by turning the timer fully clockwise. The heater should come on as indicated
by the light, and operate for one hour and then shut off automatically.
ince you most likely will use your sauna as both a "wet sauna" and a "dry sauna", you should install the sauna rocks
that have been included with the heater, following the manufacturers instructions. These stones are necessary if water
will be sprinkled on the heater to create the "wet sauna", and they will produce more consistent heating in the dry
mode (without the use of water). It is common for a stone to occasionally crack during initial heating. If excess
amounts of water are used during sauna, prop door open for 30 minutes after use to let the humidity escape.
The amount of ventilation in the sauna can be adjusted by means of the inlet vent positioned near the heater and the
outlet vent on the front wall. If the sauna is located outdoors you should keep the vents closed when the sauna is not
in use to prevent insects and rodents from entering the sauna. When using the sauna it is important that these vents
are open in order to provide fresh air flow while taking your sauna. These vents combined with the drain hole in the
floor and gaps around the door provide the proper amount of ventilation in your sauna.
ELECTRICAL
Wiring requirements for up to 30 feet distance from the breaker box are as follows:
• 4.5kw and 6.0kw heaters require 10-2 w/ground, copper only wire, and 30amp non-GFCI breaker.
• 8.0kw heaters require 8-2 w/ground, copper only wire, and 40amp non-GFCI breaker.
NOTE: All wiring must be done by a licensed electrician according to national and local electrical codes.
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TAKING A SAUNA BATH
The sauna as we know it comes from Finland. Taking a sauna bath induces excessive perspiration, which cleanses the
skin. It stimulates circulation and reduces muscular tension. It can also be an excellent relaxational or social activity.
Not to be confused with a steam bath, a sauna is a dry heat bath. The relative humidity rarely exceeds 30% even in a
wet sauna. This is because the sauna is made of porous wood and absorbs moisture. This makes higher temperatures
more tolerable.
hown below are the steps that are involved in taking a traditional bath. You may or may not want to adhere to this
regimen.
TRADITIONAL STEPS IN TAKING A SAUNA BATH
TEP #1 - et your heater so that the sauna room achieves the desired temperature, usually between 150º F and 170º
F. As a novice, you should begin at the lower end of this range and work your way up to the higher temperatures over
several sauna baths.
TEP #2 - Remove all clothing (except maybe your swimsuit), eyeglasses, contact lenses, jewelry, etc. Take a quick
shower with warm water and soap, or a quick dip in your hot tub.
TEP #3 - Enter the sauna initially for about 5 to 15 minutes. Bring a towel into the sauna onto which you can sit or lay.
Leave the sauna room once you have begun to perspire freely.
TEP #4 - Now you may take a cold plunge in your swimming pool, shower or snow bank. After that, relax and cool
down for another 10 to 20 minutes.
TEP #5 - Reenter the sauna. On this return visit you may wish to spill small amounts of water onto the rocks creating
bursts of steam. If the water spills through the heater and onto the floor, you are using too much.
TEP #6 - After your final visit to the sauna, relax for at least 20 minutes. hower with soap and warm water. Finish
your shower with cooler water to close the pores of your skin. Dress only after you have cooled down completely.
MAINTAINING YOUR SAUNA
Inside the sauna, certain areas will eventually darken due to normal use and the effects of perspiration. This can be
minimized, but not eliminated. Occasionally scrub down the inside with baking soda and water to remove the odor and
stains of perspiration. Light sanding can also be effective but should be kept to a minimum.
ACCESSORIES
Mount the thermometer on the opposite wall as the heater and no lower than 6" from the peak of the ceiling.
A wooden bucket and ladle are provided for you to sprinkle water over the hot sauna rocks.
Mount the towel hook and magazine rack where desired.
A traditional sand timer is provided and should be mounted on the opposite wall as the heater.
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ALMOST HEAVE SAUAS LIMITED WARRATY
Almost Heaven Saunas extends t is Limited Warranty solely to t e original consumer purc aser of any Almost Heaven Sauna
manufactured and installed in t e USA after April 20, 2009.
TWETY-FIVE YEAR ROOM WARRATY
Almost Heaven Saunas warrants t at t e Almost Heaven Sauna s all be free from defects in material and workmans ip under nor-
mal conditions of use and service, for a period of twenty-five (25) years for residential applications after delivery to t e original
purc aser. T is warranty is limited to making good at our factory component of t e sauna room, w ic in t e judgment of Almost
Heaven Saunas is deemed defective in materials or workmans ip. T e warranty is for material only and does not cover installation
or delivery of components.
OE YEAR POLAR HEATER WARRATY
Polar eaters are warranted by t e manufacturer against defects in workmans ip for a period of one (1) year from t e date of pur-
c ase for residential applications to t e original purc aser only. Damage caused by improper electrical ook-up or wiring voids
t e warranty. Travel, trip or mileage costs are not covered under t is warranty and service c arges will be assessed to t e pur-
c aser by t e dealer.
90 DAY IMPORT HEATER WARRATY
Restek import eaters are warranted by t e manufacturer against defects in workmans ip for a period of 90 days from t e date of
purc ase for residential applications to t e original purc aser only. Damage caused by improper electrical ook-up or wiring
voids t e warranty. Travel, trip or mileage costs are not covered under t is warranty and service c arges will be assessed to t e
purc aser by t e dealer.
EXTET OF WARRATY
T is warranty extends only to t e original “consumer” purc aser of t e sauna as t at term is defined in t e Magnuson-Moss War-
ranty Act, 15 USC Section 101, as amended. Coverage s all commence as of t e original date of purc ase and t e duration of suc
coverage s all not extend for any reason beyond t e stated time periods. T is warranty terminates upon transfer of owners ip.
WARRATY PERFORMACE
In t e event of any malfunction or defect covered by t is warranty, contact t e aut orized Almost Heaven Saunas Dealer from
w om you purc ased your sauna. In t e event t ere is not an aut orized Almost Heaven Saunas Dealer or repair firm in your area,
t e component can be returned prepaid freig t (you pay) to Almost Heaven Saunas for repair of t e defect, Almost Heaven Saunas
will t en s ip t e component back to you pre-paid (Almost Heaven Saunas pays) upon completion of t e repair. In t e event of a
return, contact Almost Heaven Saunas in advance at: Almost Heaven Saunas, HC66, Box 465-A, Renick, WV 24966, telep one
number: [phone], for packaging and s ipping instructions. In addition, Almost Heaven Saunas reserves t e rig t to inspect
or designate a person to inspect any part t at is claimed to be defective and covered by t is warranty. For any warranty service,
Almost Heaven Saunas reserves t e rig t to c oose, at its option, repair of t e problem or a replacement of t e defective part. T e
purc aser is responsible to provide adequate access to t e sauna and its equipment. Almost Heaven Saunas reserves t e rig t to
substitute a part or component of equivalent value, eit er new or factory reconditioned, and any suc repair or replacement s all
assume as its warranty only t e remaining portion of t e warranty on t e original product. Normal wear and tear, cosmetic issues
involving t e wood on components or c anges to individual pieces of lumber due to natural aging and weat ering are not covered.
ACTS IVALIDATIG WARRATY
T is warranty is void if t e Almost Heaven Sauna as been subject to alteration, misuse or abuse, or if any repairs on t e sauna are
attempted by anyone ot er t an an aut orized representative of Almost Heaven Saunas. Alteration s all include, but is not limited
to any component c ange, electrical conversion, or t e addition of any non-approved device or eating system, w ic contributes
to a component or unit failure, or unsafe operating system. Use of t e sauna in an application for w ic it is not designed will void
t is warranty. T is includes, but is not limited to, damage caused by operation of t e sauna at temperatures outside t e range speci-
fied in t e Operating Instructions, damage caused by defective components, damage to t e sauna’s surface caused by ars c emi-
cals w ic are not recommended by t e manufacturer, damage caused by movement of t e product, and damage caused by acts of
God. Wood-burning eaters are not covered under warranty by t e manufacturer or by Almost Heaven Saunas.
DISCLAIMERS
Any implied warranties arising out of an original purc aser's purc ase of an Almost Heaven sauna, including, but not limited to,
t e implied warranties of merc antability and fitness for a particular purpose, are limited in duration equal to t e duration of t e
applicable warranty stated above. Almost Heaven Saunas s all not be liable for loss of use of t e Almost Heaven Sauna or ot er
incidental or consequential costs, expenses or damage, w ic may include but are not limited to, t e removal of or reinstallation of
a wall, deck or ot er fixture, water leakage, costs of s ipping or packaging, applicable taxes, or t e payment of any costs or ex-
penses of disassembly, removal, or reinstallation of t e product or any part. Under no circumstances s all Almost Heaven Saunas
or its representatives e eld liable for injury to any person or damage to any property, owever arising, even if caused by Almost
Heaven Saunas or its representatives' negligence. Some states do not allow limitation on ow long an implied warranty lasts, and
some states do not allow t e exclusion or limitation of incidental or consequential damages, so t ese limitations or exclusions may
not apply to you. T ese warranties give you specific legal rig ts, and you may also ave ot er rig ts, w ic vary, from state to
state. No distributor, salesperson, dealer, retailer, or ot er representative of Almost Heaven Saunas as t e aut ority to alter or
c ange t ese warranties eit er orally or in writing.