In industrial combustion systems—whether power plants, refineries, or manufacturing facilities—flame detection is not just a monitoring function. It is the first and most critical line of defense against catastrophic failures. A flame that extinguishes unexpectedly while fuel continues to flow can lead to an explosive fuel-air mixture, with devastating consequences for personnel, equipment, and the surrounding environment.
This is where the ABB FAU810 Flame Analysis Unit enters the picture. As the intelligent signal processing heart of ABB‘s Uvisor™ flame monitoring system, the FAU810 transforms raw optical signals from flame scanners into actionable safety decisions—delivering high-integrity “flame on/flame off” outputs to burner management systems (BMS) and distributed control systems (DCS). Whether you are operating a coal-fired utility boiler, a gas turbine, a chemical process heater, or a waste incinerator, the FAU810 provides the precision, reliability, and connectivity you need to keep your combustion processes safe and efficient.
In this comprehensive guide from fireye-detector.com, we will cover everything you need to know about the ABB FAU810: its technical specifications, key features, application areas, installation considerations, and why it remains the standard module for all ABB flame scanner applications. We will also explain how this unit helps plant operators reduce unplanned downtime, comply with stringent safety regulations, and optimize combustion efficiency.
Chapter 1: What Is the ABB FAU810 Flame Analysis Unit?
The ABB FAU810 is not a standalone flame detector. Rather, it is an intelligent signal processing and analysis unit that serves as the “brain” of ABB‘s Uvisor™ flame monitoring system. It receives raw electrical or optical signals from flame sensors—typically installed near each burner—and processes these signals to determine whether a legitimate flame is present.
The FAU810 then outputs discrete relay signals (flame on/flame off) to the plant‘s safety system, typically a burner management system (BMS) or a safety instrumented system (SIS). When the logic determines that an unsafe condition exists—such as flame loss while fuel is still being supplied—the FAU810 triggers a “no flame” output, initiating a boiler trip or burner shutdown sequence.
Designed for Flexibility, Usability, and Reliability
According to ABB‘s official documentation, the FAU810 was “designed from the ground up for maximum flexibility, usability and reliability”. It leverages the latest available technologies to make flame analysis as cost-efficient as possible, while maintaining ABB’s rock-solid reputation as the most reliable instrument in the industry. The unit is easy to install and configure, flexible to operate, and uses redundant Profibus DP-V1 or standard Modbus interfaces for easy and safe data exchange and tuning.
One of the most compelling features of the FAU810 is its backward compatibility: it can process any type of ABB flame sensing device, from legacy DFS scanners to the latest single and multisensor Uvisor™ SF810. This makes the FAU810 the standard module for all ABB flame scanner applications and the preferred solution for retrofitting existing installations.
Chapter 2: Technical Specifications at a Glance
For engineers and procurement professionals, detailed specifications are essential. The table below summarizes the key technical parameters of the ABB FAU810 based on manufacturer documentation and verified distributor sources:
Parameter
Specification
Manufacturer
ABB
Product Series
Uvisor™ FAU 810
Product Type
Flame Analysis Unit (Signal Processing Unit)
Power Supply
Single or redundant 24 VDC (+/- 20%), built-in diode auctioneering for power source isolation
Power Consumption
Minimum 4W, typical 6W, maximum 10W
Input Channels
Two independent channels, each capable of receiving and processing one flame detector signal
Analog Outputs
Two 4-20 mA channels for independently monitoring intensity, frequency, quality, or AC amplitude
Relay Outputs
Three flame relays (Form C contacts), one fault relay
Communication Interfaces
Two galvanically isolated RS-485 interfaces supporting MODBUS (default) or PROFIBUS DP-V1 (selectable)
Self-Checking Cycle
Every 0.1 seconds
Ambient Temperature
0°C to +60°C (32°F to 140°F), 95% non-condensing
Protection Rating
IP66 (NEMA 4)
Hazardous Area Certification
ATEX II 2GD Ex d IIC T6
Dimensions (H x W x D)
130 mm × 85 mm × 35 mm (approx. 5.1″ × 3.3″ × 1.4″)
Understanding how the FAU810 processes flame signals is essential for proper system design and troubleshooting. The unit operates through a continuous four-step cycle:
Step 1: Signal Collection
The FAU810 collects raw signal values from the connected flame detector. These detectors may use ultraviolet (UV) sensing, infrared (IR) sensing, or visible light technologies, depending on the fuel type and combustion environment.
Step 2: Signal Quality Calculation
Once the raw signal is acquired, the FAU810 calculates a signal quality value. This quality measurement acts as a “barometer” that predicts when a burner is likely to go out. By monitoring trends in signal quality, plant operators can anticipate changes and take proactive measures before a flame-out actually occurs. This predictive capability is one of the FAU810‘s most powerful features, enabling condition-based maintenance rather than reactive repairs.
Step 3: Continuous Fault Detection
The FAU810 does not merely trust the incoming signal; it continuously monitors both the flame detector and its own internal electronics to detect system problems or malfunctions. The self-checking cycle runs every 0.1 seconds, ensuring that any fault—whether in the sensor, the cable, or the unit itself—is identified and reported almost immediately.
Step 4: Unsafe Condition Signaling
When the FAU810‘s logic determines that an unsafe condition exists (such as flame loss during fuel supply), it outputs a “no flame” condition. This signal is typically wired directly to the burner management system or safety instrumented system, triggering an immediate burner trip or shutdown sequence. The response time is configurable, with flame failure relay dropout adjustable from 0.2 to 4 seconds.
Chapter 4: Key Features That Set the FAU810 Apart
Dual-Channel Independence with Redundancy
Each FAU810 unit contains two independent channels, each capable of receiving and processing its own flame detector signal. The two detectors can be any combination of SF810 flame scanner heads, DFS flame scanner heads, or flame rods (ionic flame monitoring).
This dual-channel architecture provides inherent redundancy: if one channel fails, the other can continue to monitor its associated burner. For critical applications, a redundant power supply configuration is also supported, with built-in diode auctioneering for power source isolation.
Comprehensive Connectivity
The FAU810 is equipped with two galvanically isolated RS-485 interfaces for redundancy. These interfaces support both MODBUS (default) and PROFIBUS DP-V1 (selectable) protocols. PROFIBUS DP-V1 supports transmission rates up to 12 Mbit/sec, while MODBUS can connect up to 255 nodes at 115 Kbit/s.
This level of connectivity ensures seamless integration with virtually any plant control system, from legacy DCS installations to modern digital control architectures.
Onboard User Interface
Despite its compact size, the FAU810 includes a full-featured local user interface:
Graphic LCD display: 4 lines of 20 characters plus multiple bar graphs for real-time flame visualization
Four programming push-buttons: Program, Display, Up, and Down for local configuration
Four status indicator LEDs: Power, Flame #1, Flame #2, Flame #3 or Fault
Program lock: DIP switch selectable to prevent unauthorized changes
Flame Explorer Software for Remote Management
For plant personnel who need to manage multiple flame scanners across a large facility, ABB provides the Flame Explorer software package. Flame Explorer is a Windows-based configuration, data trending, and historian software tool designed to assist with initial setup and ongoing diagnostics of Uvisor™ series flame scanners.
Key capabilities of Flame Explorer include:
Continuous tracking of operating conditions
Upload/download of individual flame scanner module configurations
Logic group view for managing multiple scanners simultaneously
Password protection and OPC server connectivity (read data only)
Flame Explorer can browse up to 254 flame scanners of types FAU810 or SF810i through a single RS485 network, making it an indispensable tool for large power plants and industrial facilities.
Chapter 5: FAU810 and SF810 – The Perfect Combustion Monitoring Pair
While the FAU810 can work with any ABB flame sensing device, its most powerful synergy is with the ABB SF810 series flame scanners. The SF810 series is ABB‘s premium flame monitoring solution, designed for industrial and utility boilers operating on multiple fuels.
What makes the SF810 unique is its PYRO technology, which goes beyond basic flame detection to provide real-time flame temperature measurement for precise combustion control and improved efficiency. When paired with the FAU810‘s intelligent signal processing, network connectivity, and live diagnostics, the combination delivers:
Advanced sensing: Reliable performance even in the most challenging environments with dual-wavelength IR detection
Temperature insight: Optimization of air-fuel ratios and reduction of NOx emissions through continuous flame temperature visualization
Multi-fuel flexibility: Support for natural gas, heavy oils, coal, lignite, and biomass
Rugged design: ATEX-certified construction with IP66/IP67 protection and fiber optic options
For plants that are currently operating with outdated flame scanner systems, ABB specifically targets the FAU810 and SF810 as an economical replacement solution. By replacing only the absolutely necessary components and reusing existing wiring, cabinets, and other investments, plant operators can upgrade their combustion safety systems at a fraction of the cost of a complete replacement.
Chapter 6: Applications Across Industries
The ABB FAU810 is not limited to a single industry or application. Its flexibility and robust design make it suitable for a wide range of combustion monitoring scenarios:
Power Generation (Utility and Industrial Boilers)
In coal-fired, gas-fired, and oil-fired power plants, the FAU810 provides continuous flame monitoring for each individual burner. This is particularly critical in large utility boilers where a single undetected flame-out could lead to a dangerous fuel-rich condition. The FAU810‘s ability to define a wide range of limit values allows it to account for any situation that may arise in utility or industrial boilers.
Gas Turbines
Gas turbine combustion systems operate under extreme temperatures and pressures. The FAU810, when paired with appropriate flame detectors, provides reliable flame presence verification even under these demanding conditions. Its fast response time ensures that any flame instability is detected and reported before it can escalate.
Chemical and Petrochemical Process Heaters
In refineries and chemical plants, process heaters are used to raise the temperature of feedstocks for further processing. A flame-out in a process heater can have serious consequences, including the release of unburned hydrocarbons. The FAU810 provides the high-integrity flame detection required for these critical safety applications.
Waste Incinerators
Municipal and hazardous waste incinerators must maintain continuous combustion to ensure complete destruction of waste materials. The FAU810 provides reliable flame monitoring even when fuel composition varies widely.
Cement Kilns
In cement production, the main burner at the kiln‘s discharge end must maintain a stable flame to ensure proper clinker formation. The FAU810‘s signal quality measurement helps operators anticipate flame instability before it affects product quality.
Flare Stacks
Flare stacks are used to safely combust waste gases in refineries and chemical plants. The FAU810 can be used to verify that the flare is ignited and burning properly, ensuring compliance with environmental regulations.
Chapter 7: Why Retrofitting with the FAU810 Makes Economic Sense
Many industrial facilities are still operating with flame scanner systems that were installed 15, 20, or even 30 years ago. While these legacy systems may still function, they often suffer from:
Obsolescence: Replacement parts are increasingly difficult to find and expensive when available.
Limited diagnostics: Older systems provide minimal insight into signal quality or impending failures.
Poor connectivity: Legacy systems often lack modern digital communication protocols, making integration with modern DCS systems difficult.
Higher nuisance trip rates: Older analog systems are more susceptible to false readings from background radiation or adjacent burner flames.
The FAU810 directly addresses each of these pain points:
Economical Replacement Strategy
ABB has specifically designed the FAU810 and SF810 as an economical replacement for outdated flame scanner systems. By reusing existing wiring, cabinets, and other infrastructure investments, plant operators can upgrade their flame detection capabilities without incurring the full cost of a greenfield installation.
Future-Proof Connectivity
With redundant PROFIBUS DP-V1 and MODBUS interfaces, the FAU810 integrates seamlessly with modern DCS and PLC systems. This connectivity enables remote monitoring, data logging, and integration with plant-wide safety systems—capabilities that are simply not available with legacy analog flame amplifiers.
Reduced Nuisance Trips
Nuisance burner trips—where the flame detection system incorrectly reports flame loss—are a major source of unplanned downtime and lost production. The FAU810‘s advanced signal processing algorithms, combined with its ability to define a wide range of programmable limit values, significantly reduces the incidence of nuisance trips compared to older analog systems.
Chapter 8: Safety and Compliance Considerations
Flame detection systems are classified as safety instrumented functions (SIFs) under standards such as IEC 61508 and IEC 61511. The FAU810 is designed with safety in mind:
Continuous Self-Checking
The FAU810 performs a self-checking cycle every 0.1 seconds, monitoring both the connected flame detectors and its own internal electronics for any faults. If a fault is detected, the unit can be configured to output a “no flame” condition (fail-safe) or a fault alarm, depending on the application requirements.
Fail-Safe Relay Design
The flame relays in the FAU810 are designed to drop out (de-energize) when a flame is not present. This fail-safe design means that any loss of power, wiring fault, or internal failure will result in a “no flame” output—the safest possible condition.
ATEX Certification
For installations in potentially explosive atmospheres, the FAU810 is available with ATEX II 2GD Ex d IIC T6 certification. This allows the unit to be installed in Zone 1 and Zone 2 hazardous areas without requiring additional explosion-proof enclosures.
Chapter 9: Installation and Commissioning Tips
Proper installation is essential for reliable FAU810 operation. Based on industry best practices and ABB documentation, here are key considerations:
Power Supply
The FAU810 can be powered from a single or redundant 24 VDC source (+/- 20%). For critical applications, ABB recommends using a redundant power supply configuration with the built-in diode auctioneering for power source isolation. The typical power consumption is 6 watts, so standard industrial power supplies are sufficient for most installations.
Wiring
For maximum noise immunity, use shielded twisted-pair cable for the RS-485 communication lines. Maintain proper grounding practices to prevent ground loops, which can cause erratic communication or false flame signals.
Flame Detector Compatibility
The FAU810 is compatible with:
All SF810 flame scanner heads
All DFS flame scanner heads
Flame rods (ionic flame monitoring)
When using flame rods, ensure that the ionic current is within the FAU810‘s detection range.
Distance Limitations
The maximum distance between an SF810 scanner and the FAU810 is 500 meters (1500 feet). For longer distances, fiber optic extensions may be required.
Configuration
The FAU810 can be configured locally using the onboard LCD display and programming buttons, or remotely using the Flame Explorer software. Key configurable parameters include:
Flame failure relay dropout time (0.2 to 4 seconds)
Sensitivity settings for each channel
Frequency filtering parameters
4-20 mA output scaling for intensity, frequency, quality, or AC amplitude
As a specialized supplier of industrial combustion monitoring equipment, fireye-detector.com is your trusted source for the ABB FAU810 Flame Analysis Unit and related accessories. Here is why plant operators and maintenance professionals choose us:
100% Genuine ABB Products
Every FAU810 unit we supply is 100% genuine ABB product, sourced directly from authorized distribution channels. We do not sell counterfeit or refurbished units labeled as new.
Competitive Pricing
Thanks to our direct relationships with ABB‘s distribution network, we offer competitive pricing on all FAU810 models, including the C10-12010 and C87-11006 variants. We also offer volume discounts for plant-wide retrofits and multi-unit purchases.
Fast Worldwide Shipping
We maintain an inventory of FAU810 units and compatible SF810 scanners ready for immediate shipment. Using DHL Express, FedEx Priority, and UPS Worldwide, we deliver to over 80 countries with typical transit times of 3–7 business days.
12-Month Warranty
All FAU810 units from fireye-detector.com come with a comprehensive 12-month warranty against manufacturing defects and premature failure.
Technical Support from Experienced Engineers
Our team includes engineers with direct experience in ABB flame scanner systems. Whether you need help selecting the correct FAU810 variant, troubleshooting a configuration issue, or planning a plant-wide retrofit, we are here to help.
30-Day Return Policy
If the product you receive does not meet your expectations, we offer a 30-day return policy for quality-related issues.
Conclusion: Secure Your Combustion Process With the ABB FAU810
Flame detection is not a luxury; it is a safety imperative. The ABB FAU810 Flame Analysis Unit represents the state of the art in intelligent flame signal processing, combining dual-channel redundancy, continuous self-diagnostics, flexible connectivity, and backward compatibility with legacy ABB flame detectors.
Whether you are building a new power plant, retrofitting an aging flame scanner system, or simply replacing a failed flame amplifier, the FAU810 delivers the reliability, accuracy, and connectivity you need to keep your combustion processes safe and efficient.
At fireye-detector.com, we are committed to helping plant operators and maintenance professionals find the right flame monitoring equipment for their specific applications. Contact us today for a competitive quote on the ABB FAU810, or browse our complete catalog of ABB flame scanners and accessories.
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