Troubleshooting ABB FAU810 Flame Detector
ABB FAU810 Flame Detector: Common Issues and Engineering Solutions
Introduction
In many industrial combustion systems, maintaining reliable flame detection is critical for safety and process control. The ABB FAU810 flame detector provides ultraviolet and infrared sensing for gas, oil, and coal-fired burners. However, field applications often encounter operational challenges that can compromise signal reliability. This article addresses common issues, diagnostic methods, and engineering solutions for the FAU810.
1. System Background and Typical Applications
The FAU810 is widely used in power generation, chemical plants, and industrial boilers. In these systems, burner flame status must be accurately reported to the control logic. Delayed or missing signals can cause false shutdowns or unsafe conditions. Common installation environments include high-temperature furnaces, dusty or humid environments, and areas with electrical noise.
2. Common Operational Issues
a. No Flame Signal Detection
One of the most frequently reported issues is the detector failing to register a flame. Possible engineering causes include:
Misalignment between the detector and the burner flame axis
Contamination of the optical window with soot or dust
Electrical interference from nearby motors or inverters
b. False Flame Alarms
Unintended alarms may be triggered due to:
Reflections from furnace walls or metallic surfaces
Nearby UV or IR sources unrelated to the flame
Detector sensitivity settings outside the recommended range
c. Signal Instability
Intermittent signals can arise from:
Loose wiring or connectors
Rapid fluctuations in flame size or fuel composition
Vibrations affecting detector stability
3. Engineering Solutions
a. Installation and Alignment
Ensure the FAU810 is mounted with a clear line of sight to the flame
Use mechanical brackets to minimize vibration
Adjust the detector axis according to manufacturer guidelines
b. Optical Maintenance
Regularly clean the detector window to remove soot, dust, and residue
Inspect for scratches or clouding that may reduce sensitivity
c. Electrical and Signal Management
Check all cable connections and grounding points
Shield wiring from high-voltage lines or electrical noise sources
Verify power supply stability and correct voltage levels
d. Sensitivity and Configuration
Set sensitivity according to fuel type and burner characteristics
Adjust response time to accommodate fast or slow flame fluctuations
Calibrate the detector following ABB recommended procedures
4. Limitations and Non-Recommended Applications
The FAU810 should not be used in:
Extremely high vibration zones without proper mounting
Environments with excessive electromagnetic interference
Applications requiring continuous analog flame measurement
Understanding these limitations is critical to avoid misapplication and ensure long-term reliability.
5. Field Diagnostics and Preventive Measures
Perform regular inspections and functional tests
Document flame response times and alarm occurrences
Replace detectors showing repeated false signals despite correct installation
Maintain a spare parts inventory for quick replacement
6. Summary
ABB FAU810 flame detectors are robust components in industrial combustion safety systems. Proper installation, alignment, and maintenance are essential to prevent operational issues. Engineering-focused troubleshooting ensures accurate flame detection, reduces false alarms, and maintains system safety and efficiency. By adhering to these technical guidelines, industrial engineers can optimize the performance of FAU810 detectors across various applications.