Calspas Cal Heat IR-100 User manual

Due to continuous improvement programs, all models, operation, and/or specifications are subject to change without prior notice.
$5.00
2005 Owner’s Manual
INFRARED AND
OUTDOOR SAUNAS
manufactured after December 1, 2004
www.calspas.com
LTR20051009, Rev. 12/17/04

12/17/04
CONTACT INFORMATION
For customer service, please contact your authorized dealer
immediately. If you need additional information and/or
assistance, please contact:
C.A.I. Customer Service Department
1462 East Ninth Street
Pomona, CA 91766
Toll Free: 1-800-CAL-SPAS
Fax: [phone]
www.calspas.com
Copyright 2004, 2005 California Acrylic Industries, Inc. All rights reserved. Duplication
without written consent is strictly prohibited.
Cal Spas™ and Cal Heat™ are registered trademarks.
Due to continuous improvement programs, all models, operation, and/or specifications are subject to
change without prior notice.
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Read This First!
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Preparing for Your New Sauna
Planning the Best Location For Your Sauna . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Electrical Set-Up Before Delivery of Your Sauna . . . . . . . . . . . . . . . . . . . . . . . . .5
Preparing a Good Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Assembling Your Sauna
IR-100 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
IR-200 Infrared Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
OD-100 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
OD-200 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Operating Your Sauna
IR-100 and IR-200 Infrared Models Control Touch Pad . . . . . . . . . . . . . . . . . .23
Using the Marine Grade Audio System
Using the Clarion Stereo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Cleaning and Maintaining Your Sauna
Appendix
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Table of Contents
Sauna Owner’s Manual
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Read This First!
Safety Instructions
Carefully read and follow all safety instructions.
1. When installing and using this electrical equipment, basic safety precautions should always be
followed.
2. To reduce the risk of injury, do not allow children to use this equipment unless they are supervised
at all times.
3. Do not use this equipment immediately following strenuous exercise. Wait at least 30 minutes to
allow the body to cool down completely.
4. Excessive temperatures have a high potential for causing damage during the early months of preg-
nancy. Pregnant, or possibly pregnant, women should contact their physician prior to using this
equipment.
5. The use of alcohol, drugs, or medications prior to or during the session may lead to unconscious-
ness.
6. Persons suffering from obesity, a medical history of heart disease, low or high blood pressure,
circulatory system problems, or diabetes should consult a physician prior to using this product.
7. Persons using medications should consult a physician before using the equipment since some
medications may induce drowsiness, while others may affect heart rate, blood pressure, and circu-
lation.
8. Exercise safety when entering and exiting.
9. Never sleep inside while in the unit is in full operation.
10. Do not use any type of cleaning agents on the interior of this product.
11. Do not stack or store any objects on top of or inside the equipment.
12. If the power supply cord becomes damaged, it must be immediately replaced by a C.A.I. certified
technician or licensed electrician to avoid hazard.
13. Do not use an outdoor unit during an electrical storm., as there is a remote chance of shock.
14. Altering or tampering of any electrical connections on the power supply will void the manufac-
turer’s warranty.
15. Dry your hands before handling electrical controls. Never unplug the power cord or adjust the
controls with wet hands or when you have wet bare feet. A danger of electrical shock exists.
16. Do not attempt any repair without consulting the manufacturer first. Unauthorized repair attempts
will void the manufacturer’s warranty.
17. We strongly recommend the use of a ground fault circuit interrupter (GFCI) device in any poten-
tially wet locations, or the manufacturer’s warranty is void..
18. We recommend turning on the equipment for the maximum allowable time period and tempera-
ture in order to burn off any factory dust prior to using the equipment for the first time.
Hyperthermia Danger
Prolonged exposure to hot air/water can induce hyperthermia. Hyperthermia occurs when the internal
temperature of the body reaches a level 3-6 degrees above the normal body temperature of 37ºC (98.6ºF)
While hyperthermia has many health benefits, it is important not to allow your body’s core temperature to
rise above 103ºF. Symptoms of excessive hyperthermia include dizziness, lethargy, drowsiness and faint-
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ing. The effects of excessive hyperthermia may include failure to perceive heat, failure to recognize the
need to exit, unawareness of impending hazard, damage to pregnant women, physical inability to exit the
unit and unconsciousness.
Following these procedures will make your sauna sessions pleasurable.
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Preparing for Your New Sauna
Most cities and counties require permits for exterior construction and electrical circuits. In addition, some
communities have codes requiring residential barriers such as fencing and/or self-closing gates on prop-
erty to prevent unsupervised access to the property by children under the age of 5. Your dealer can pro-
vide information on which permits may be required and how to obtain them prior to the delivery of your
equipment.
Planning the Best Location For Your Sauna
Here are some of the things that you will need to consider when determining where to place your new
sauna.
Safety First
• Do not place your sauna within 10’ (3m) of overhead power lines.
• Make sure it is positioned so that access to the equipment compartment and all side panels will not be
blocked. Be certain that your installation will meet all city and local safety codes and requirements.
Consider How You Will Use Your Sauna
How you intend to use your sauna will help you determine where you should position it. For example,
will you use your sauna for recreational or therapeutic purposes? If your sauna is mainly used for family
recreation, be sure to leave plenty of room around it for activity. If you will use it for relaxation and ther-
apy, you’ll probably want to create a specific mood around it.
NOTE: Only the OD-100 and the OD-200 models are meant for an outdoor application. The IR-100
and IR-200 models are meant for indoor use ONLY. The outside of these models have not
been treated for outdoor use. Extreme hot/cold conditions can cause the wood to blister, split and
warp. This will void the warranty of these particular models.
Plan for Your Environment
If you live in a climate with snowfall in the winter, place the sauna near a house entry. By doing this, you
will have a place to change clothes and not be uncomfortable. This would be a convenient way to go for
the location of your sauna outdoors.
Indoor installations require adequate ventilation. When the sauna is in use, considerable amounts of heat
and dryness are produced. This heat and dryness can damage walls and ceiling surfaces over a period of
time. Special paint is available to resist this damage.
Consider Your Privacy
In a cold- weather climate, bare trees won’t provide much privacy. Think of your sauna’s surroundings
during all seasons to determine your best privacy options. Consider the view of your neighbors as well,
when you plan the location of your sauna.
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Provide A View With Your Sauna
Think about the direction you will be facing when sitting in your sauna. Do you have a special landscaped
area in your yard that you find enjoyable? Perhaps there is an area that catches a soothing breeze during
the day and lovely sunset in the evening. Consider these things when you plan your location.
Keep Your Sauna Clean
Prevent dirt and contaminants from being tracked into your sauna by using a foot mat at the entrance
where the occupants can clean their feet before entering your sauna.
Allow For Service Access
Many people choose to install a decorative structure around their sauna. If you are installing your sauna
with any type of structure on the outside (OD-100 and OD-200 models only), remember to allow access
for service. It is always best to design special installations so that the sauna can still be moved, or lifted
off the ground.
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Electrical Set-Up Before Delivery of Your Sauna
IMPORTANT:: When installed in the United States, the electrical wiring of this sauna must meet the
requirements of the National Electric Code (NEC) and any applicable state or local codes. The electrical
circuit must be installed by an electrical contractor and approved by a local building/ electrical inspector.
1. All 240V saunas must be permanently connected (hard wired) to the power supply. 120V saunas may
use a G.F.C.I. cord, plugged into a dedicated grounded outlet. Supplying power to a sauna which is
not in accordance with these instructions will void both the independent testing agency’s listing and
the manufacturer’s warranty.
2. The power supplied to the sauna must be on a dedicated circuit with no other appliances or lights
sharing the power.
3. To determine the current, voltage, and wire size required for the sauna configuration to be connected,
refer to the following:
•Wire size must be appropriate per NEC and/or local codes.
•Wire size is determined by length of run from breaker box to sauna and maximum current draw.
•We recommend copper wire with THHN insulation.
• All wiring must be copper to ensure adequate connections. Do not use aluminum wire.
• When using wire larger than #6 (10mm2), add a junction box near the spa and reduce to short lengths
of #6 (10mm2) wire between the junction box and the sauna.
4. The electrical supply for the sauna must include a suitably rated switch or circuit breaker to open all
ungrounded supply conductors to comply with Section 422-20 of the National Electric Code,
NSI/NFPA 70. The disconnection point must be readily accessible to the sauna’s occupant. Check with
local municipalities for additional code requirements.
5. The electrical circuit for the sauna must include a suitable ground fault circuit interrupter (GFCI) as
required by NEC Article 680-42.
ELECTRICAL INSTALLATION OFYOUR SAUNAAFTER DELIVERY
Important Safety Notice For All Models
1. Access the sauna’s power terminal strip.
NOTE: For the IR-100 Infrared and IR-200 Infrared models, locate the junction box (located under
neath the bench; this can be accessed by removing the front skirt of the bench). Make sure that all
the connections are seated securely in the junction box.
2. Plug the unit in.
Preparing a Good Foundation
Your sauna needs a solid and level foundation. The area that it sits on must be able to support the weight
of the sauna and the occupants who use it. If the foundation is inadequate, it may shift or settle after the
sauna is in place, causing stress that could alter the structures seal.
NOTE: Damage caused by inadequate or improper foundation support is not covered by the warranty. It
is the responsibility of the sauna owner to provide a proper foundation for the sauna.
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Place the sauna on an elevated foundation (preferably a 3” concrete slab). If you are installing the sauna
indoors, pay close attention to the flooring beneath it. Choose flooring that won’t be spoiled or stained.
Below are the recommended foundation sizes for your sauna (Extreme models only)
Sauna Actual Size Recommended Size
OD-100 Sauna 4’x 6’ 5.5’x 7.5’
OD-200 Sauna 5’x 8’ 6.5’x 9.5’
If you are installing your sauna on an elevated wood deck or other structure, it is highly recommended
that you consult a structural engineer or contractor to ensure the structure will support the weight.
We strongly recommend that a qualified, licensed contractor prepare the foundation for your sauna.
Your Cal Heat Retailer Can Help You With Foundation And More
Your retailer has a wealth of information and experience about how to get the most out of your sauna.
Your sauna retailer also has a full line of accessories that are engineered to complement your sauna.
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Check the Dimensions of Your Sauna
The Size Specifications chart for your sauna is listed below. Compare the dimensions to the width of
gates, sidewalks, doorways, hallways, etc. along the delivery route that will be used when building your
sauna in the desired location. It may be necessary for you to remove some items in order to provide an
unobstructed passageway to the installation location.
Size Specifications
Model Depth Width Height
IR-100 Infrared 4’ 4’ 6’
IR-200 Infrared 4’ 5’ 6’
OD-100 Outdoor 4’ 6’ 7’
OD-200 Outdoor 5’ 8’ 7’
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Assembling Your Sauna
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Assembling Your Sauna
Cal Heat has 4 models in the infrared / outdoor series to choose from, depending on your particular need.
The following figures display each model.
Each model has different assembly instructions. The IR-100 and IR-200 infrared models have a different
wiring plan (each heater must be plugged into a junction box located beneath the middle bench).
Remove the packaging panel marked “OPEN THIS END” first to access the contents. Once the panel is
removed, unscrew the cross-member support from inside the crate. Remove the contents from the crate
and assemble in a place with adequate room. Please refer to the Appendix section for the parts list and
verify that your sauna model is complete.
Tool List
Portable Drill
Screw Driver
Rubber Mallet
Estimated Time for Completion:
IR-100 and IR-200 2 hours 15minutes
OD-100 and OD-200 2 hours 30 minutes
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IR-100 Assembly
The following steps refer to Figure 1.
1. Assemble the side bench. Screw the legs into the underside cross-support of the bench (A). After
assembling the bench, place the bench on the wooden flooring of the sauna.
2. Assemble the main bench, following the steps in Step 1.
3. Attach the bench shirt to the side bench using the provided screws. There are two pre-drilled holes
that are located near the edge of the bench. This is the front of the bench.After attaching the skirt,
place two wooden plugs in the holes and gently tap into place.
4. The skirt for the main bench has the bench heater already attached to it. While looking at the bench
heater, make sure the heater is to your right. Attach the bench heater skirt using the provided screws
(see Step 3). Gently tap the wooden plugs into the holes.
5. Place the wall panels against the flooring and attach the panels (with the provided screws) to each
corner. Repeat these steps, as necessary, to complete the wall assembly.
Figure 1. IR-100 assembly
6. Take six 3”-wide decorative strips and attach them to each corner. The two corners in the front of the
sauna will have a strip on each side. The corners at the back of the sauna will one strip on each visible
corner.
7. Place roof top panel onto the wall panel assembly. Place the 1” x 2” roof supports, inside the sauna,
up against the roof top (Figure 2).
8. Place the outside trim piece(s) flush with top of the roof.
9. Plug in all seven male heater plugs into the corresponding female receptacles on the junctions box
(Figure 3).
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10. Plug the light fixture into the receptacle on the side of the junction box.
11. Plug the heat sensor into the rear of the junction box.
12. Plug the control panel touch pad into the rear of the junction box (this connector has a telephone-type
plug).
NOTE: It is advised that all electrical connections be made by a licensed electrician. Some sauna models
are 220V. Check with your dealer to make sure what your sauna is.
Figure 2. IR-100 assembly
Figure 3. IR-100 electrical plan
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Light Installation (Both Inside/Outside)
1. Use the decorative light for the outside. Attach the black wires to each other and attach the white
wires to each other. Tuck the excess wires into the junction box and tighten the mounting screws. A
100W light bulb is recommended for outside use.
2. Use the gray, commercial-grade light for the inside. Attach the black wires to each other and attach
the white wires to each other. Tuck the excess wires into the junction box and tighten the mounting
screws. A 60W soft-white light bulb is recommended for outside use.
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IR-200 Infrared Assembly Instructions
NOTE: The following steps refer to Figure 4.
1. Assemble the side bench. Screw the legs into the underside cross-support of the bench (A). After
assembling the bench, place the bench on the wooden flooring of the sauna.
2. Assemble the main bench, following the steps in Step 1.
3. Attach the bench shirt to the side bench using the provided screws. There are two pre-drilled holes
that are located near the edge of the bench. This is the front of the bench.After attaching the skirt,
place two wooden plugs in the holes and gently tap into place.
4. The skirt for the main bench has the bench heater already attached to it. While looking at the bench
heater, make sure the heater is to your right. Attach the bench heater skirt using the provided screws
(see Step 3). Gently tap the wooden plugs into the holes.
5. Place the wall panels against the flooring and attach the panels (with the provided screws) to each
corner. Repeat these steps, as necessary, to complete the wall assembly.
Figure 4. IR-200 assembly
6. Take six 3”-wide decorative strips and attach them to each corner. The two corners in the front of the
sauna will have a strip on each side. The corners at the back of the sauna will one strip on each visible
corner.
7. Place roof top panel onto the wall panel assembly. Place the 1” x 2” roof supports, inside the sauna,
up against the roof top (Figure 5).
8. Place the outside trim piece(s) flush with top of the roof (Figure 5).
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Figure 5. IR-200 assembly
9. Plug in all seven male heater plugs into the corresponding female receptacles on the junctions box.
10. Plug the light fixture into the receptacle on the side of the junction box.
11. Plug the heat sensor into the rear of the junction box.
12. Plug the control panel touch pad into the rear of the junction box (this connector has a telephone-type
plug).
NOTE: It is advised that all electrical connections be made by a licensed electrician. Some sauna models
are 220V. Check with your dealer to make sure what your sauna is.
Figure 6. Electrical plan
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Light Installation (Both Inside/Outside)
1. Use the decorative light for the outside. Attach the black wires to each other and attach the white
wires to each other. Tuck the excess wires into the junction box and tighten the mounting screws. A
100W light bulb is recommended for outside use.
2. Use the gray, commercial-grade light for the inside. Attach the black wires to each other and attach
the white wires to each other. Tuck the excess wires into the junction box and tighten the mounting
screws. A 60W soft-white light bulb is recommended for outside use.
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OD-100 Assembly
The assembly of this sauna will require no less than three people. The panels, roof top and roof assembly
are heavy and difficult to lift with by only one person.
The following steps refer to Figures 7, 8, and 9.
1. Assemble the bench. Screw the legs into the underside cross-support of the bench (Figure 7). After
assembling the bench, place the bench on the wooden flooring of the sauna.
2. Place the heater bottom support on the front left corner and the place the heater on top of the heater
support.
3. Place the wall panels against the flooring and attach the panels (with the provided screws) to the
flooring. Attach the center pieces and place between the two front and two back panels. Then place
the corner piece and attach it to the wall panels. Repeat these steps, as necessary, to complete the wall
assembly.
Figure 7. OD-100 assembly
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Assembling Your Sauna
4. Place roof top panel onto the wall panel assembly. Place the 1” x 2” roof supports, inside the sauna,
up against the roof top (Figure 8).
5. Place the outside trim piece(s) flush with top of the roof.
6. Place the heater bracket around the heater and secure it in place.
WARNING: IT WILL TAKE TWO OR MORE PEOPLE TO INSTALL THE ROOF TOP. DO NOT
ATTEMPT TO LIFT IT BYYOURSELF.
Figure 8. OD-100 assembly
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Chapter Title