ABB SF810INT-FOC-IR-L | Flame Detection Sensor | Obsolete Combustion Safety Component Risk
ABB SF810INT-FOC-IR-L | Flame Detection Sensor | Obsolete Combustion Safety Component Risk - Image 2
ABB SF810INT-FOC-IR-L | Flame Detection Sensor | Obsolete Combustion Safety Component Risk - Image 3

ABB SF810INT-FOC-IR-L | Flame Detection Sensor | Obsolete Combustion Safety Component Risk

  • Model: SF810INT-FOC-IR-L
  • Brand: ABB (formerly part of the ABB Ability™ Safe Torque family; flame detection product line historically sourced from third-party OEMs under ABB branding)
  • Core Function: Infrared (IR)-based multi-spectrum flame detector for monitoring hydrocarbon flames in industrial burners, boilers, and turbines
  • Lifecycle Status: Obsolete
  • Procurement Risk: High – no longer listed in current ABB catalogs; supply limited to surplus or used channels with uncertain calibration status
  • Critical Role: Provides real-time flame presence verification to burner management systems (BMS); failure may lead to unsafe fuel release or nuisance shutdowns
Category: SKU: ABB SF810INT-FOC-IR-L

Description

Technical Specifications (For Spare Parts Verification)

  • Product Model: SF810INT-FOC-IR-L
  • Manufacturer: ABB (OEM-supplied, likely based on legacy Spectrex or Honeywell technology)
  • Detection Principle: Infrared (IR) multi-band flame recognition (typically 2–5 µm range)
  • Output Type: Relay contact (flame present / fault) and/or 4–20 mA analog signal (depending on configuration)
  • Field of View: Fixed-focus optical system, typically ~90° horizontal by ~60° vertical
  • Housing Rating: Explosion-proof (e.g., ATEX II 2G Ex d IIC T6, IECEx, or CSA Class I Div 1)
  • Sight Tube Compatibility: Designed for use with standard 1″ NPT purge-type sight tubes
  • Operating Temperature: –40°C to +70°C (electronics head); higher with cooling jacket
  • Power Supply: Typically 24 VDC (verify unit label—some variants support 115/230 VAC)
  • Response Time: < 3 seconds to flame loss (per EN 54-10 or FM 3260 standards)
  • Diagnostic Features: Internal self-test, window contamination alarm (if equipped), LED status indicator

System Role and Downtime Impact

The ABB SF810INT-FOC-IR-L is deployed as a critical safety device in combustion applications such as utility boilers, thermal oxidizers, and process heaters. It continuously analyzes infrared radiation patterns to distinguish real hydrocarbon flames from background sources (e.g., hot refractory, sunlight, or welding). Its output directly interfaces with safety PLCs or dedicated flame safeguard panels to enable or cut fuel flow. If the detector fails in a “safe” state (no flame detected), it triggers an immediate burner trip—halting production and requiring manual reset. More critically, a dangerous failure (falsely indicating flame presence during actual flameout) could allow unignited fuel to accumulate, creating explosion hazards. In regulated industries, either scenario may violate NFPA 85, API 556, or IEC 61511 requirements, exposing operators to compliance and safety liabilities.

 

Reliability Analysis and Common Failure Modes

Despite rugged construction, this generation of IR flame detectors exhibits several predictable aging issues:

  1. Optical window degradation: The sapphire or quartz lens can become coated with soot, oil mist, or salt deposits in harsh environments, attenuating IR signals and causing false “flame lost” alarms. Thermal cycling may also induce micro-cracks.
  2. IR sensor drift: Pyroelectric or photodiode-based IR elements lose sensitivity over time, especially when exposed to high ambient temperatures near the burner throat.
  3. Moisture ingress: Failed seals or inadequate purge air allow condensation inside the housing, leading to corrosion of internal electronics or short circuits.
  4. Power supply instability: Voltage fluctuations or ground loops can disrupt internal microprocessor logic, triggering spurious fault conditions.

Recommended preventive maintenance includes:

  • Quarterly visual inspection of lens clarity and housing integrity
  • Functional testing using certified IR flame simulators during scheduled outages
  • Verification of purge air pressure and filtration (if applicable)
  • Ensuring proper grounding and shielded cabling per installation manuals

Units installed before 2015 are likely operating beyond their recommended service life.

Lifecycle Status and Migration Strategy

ABB no longer markets the SF810INT series, having consolidated its flame detection portfolio under newer platforms or strategic partnerships. Official technical support and factory repairs are unavailable, and replacement units cannot be ordered through standard channels. Continued reliance on this hardware introduces significant operational and safety risk.

As interim measures, facilities can:

  • Secure one or two verified spares with recent calibration certificates
  • Implement dual-detector voting logic to mitigate single-point failure
  • Use external air purge systems to reduce lens fouling and extend service intervals

For long-term sustainability, migration to modern alternatives is essential. Recommended replacements include:

  • ABB’s current flame detection partners (e.g., Spectrex SharpEye 40/40 series or Honeywell X3300) offering UV/IR or triple-IR technology with built-in diagnostics
  • Devices compliant with IEC 61508 SIL 2/3 and supporting HART or Modbus for integration into modern BMS

Migration typically requires minor mechanical adaptation (mounting thread or sight tube) and re-commissioning of safety logic—but delivers improved reliability, reduced false alarms, and extended lifecycle support. Initiating this upgrade during planned maintenance windows is strongly advised to eliminate obsolescence-driven safety exposure.

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