The more substantial the heat exchanger, the more heat is retained, the higher the efficiency of the system. Thick cast iron walls naturally retain heat longer, thereby requiring minimal system cycling. Saving energy, saving costs, and saving the system from unnecessary wear and tear. Plus each of Ray’s patented components is designed to exact engineering specifications to provide maximum heat from the burner.

The steady thermal retention of Ray’s cast iron heat exchanger keeps temperatures inside the boiler stable, preventing thermal shock caused by the sudden introduction of cold return water inside the boiler. Ray is built to provide a good, long life.

Condensates and water vapor come with the territory for condensing boiler systems, but with the Ray boiler they are never a problem. Its down-fired design helps remove acidic residues that are then filtered out through a condensate collector.

Among the many benefits of cast iron, the material exhibits virtually no fatigue from expansion and contraction so fissures cannot be created in which condensates can collect. The cast iron heat exchanger's thick wall design easily withstands the corrosive potential of condensates until they are discharged. The heavy duty exchanger also retains heat more effectively than tubular heat exchangers, offsetting condensation.

Unlike heat exchangers with tubular construction, where the dimensions and proportions of the exchanger are dictated by the material’s limitations, the Ray heat exchanger is cast according to exacting design. Integrating this level of control into Ray’s total, end-to-end manufacturing process (see “Manufacturing” tab for more info) creates a heat exchanger compatible with performance demands as well as associated components.

Basically, mold forming means starting with what would be ideal, and going forward to design each section from there. With tube-formed exchangers, manufacturers have to start with the limitations of the material and work backwards.

Homeowners want enduring value, contractors want low maintenance: Ray’s mold formed exchanger helps make both happen.

The Ray boiler is designed, developed and manufactured from start to finish in one US facility. That means, unlike other boilers that outsource such crucial components as the heat exchanger itself, Ray maintains total quality control from base metal to final assembly. Several components are custom-made for the Ray boiler so that there is never a compromise from design to implementation. Every part and material is tested to the highest industry requirements.

This integrated manufacturing process not only guarantees a highly efficient, effective and reliable product for today, it ensures long-term compatible performance long into the future.

If you want to find out more, click on the “How it’s Made” tab at the top of the page.