Danny Rose’s disastrous late winner ended the 10-man Clarets’ cup hopes following a lifeless third round clash at Oakwell.
A dour tie appeared to be heading to a stalemate following Brian Stock’s first half dismissal, before Brian Jensen misjudged Scott Golbourne’s hopeful 86th minute punt into the Burnley box.
And after only succeeding in tipping the ball onto the face of the crossbar, Rose blasted the ball into the roof of the net from close range to win it for the Tykes.
Burnley were left to rue the sending off of Stock for two yellow cards, firstly following an off the ball tussle with Marlon Harewood and then for a blatant tug on Jim O’Brien’s shirt.
Sand despite the sterling efforts of lone frontman Sam Vokes, the only other positive to take from a below-par display was the introduction of Jamaican winger Dane Richards, who caused a few flutters in the Tykes’ defence on his debut in English football.
Jensen had returned to the starting line-up in goal, with Dean Marney returning from injury and Keith Treacy starting following his match-winning mid-week performance at Sheffield Wednesday.
Richards, meanwhile, received international clearance following his move from Vancouver Whitecaps and was joined on the bench by young striker Wes Fletcher.
In front of a sparse crowd, albeit with plenty of support crossing the Pennines, Burnley started well and created their best opening of the game in the eighth minute.
Ings, starting on the right, picked up the ball through the middle and ran at the heart of the defence before sliding in Sam Vokes on the left side of the area.
The Welshman wrapped his right foot around the ball, but got his angles just wrong and the curling shot flew across Luke Steele and just wide of his far post.
As the Clarets continued to press in the early stages, Michael Duff headed over Ross Wallace’s left wing free kick and the wide man forced Steele to turn away his deflected cross underneath his crossbar.
Barnsley had made one change, with Harewood replacing seemingly Bolton-bound striker Craig Davies.
But the Tykes’ striker’s only contribution of the opening half was a spot of off-the-ball argy-bargy as the hosts’ prepared to take a free kick, which resulted in both Harewood and Stock both entering the referee’s notebook.
And the significance of that hit home eight minutes before half time when Stock received his marching orders following a second yellow card for a tug on the shirt, as O’Brien looked to wriggle into a shooting position.
As Barnsley looked to make their numerical advantage count, David Perkins curled a shot just over Jensen’s bar from distance.
And in the dying seconds of the half, Burnley had a lucky escape when Scott Golbourne blazed over with just Jensen to beat on the left side of the box.
Treacy made way for David Edgar at the break as the 10-man Clarets re-grouped.
But the pendulum continued to swing Barnsley’s way and Stephen Dawson should have done better 90 seconds into the half with a bobbled, off-target effort when a half-cleared corner fell to him on the edge of the box.
And the midfielder skied an equally presentable opportunity 10 minutes into the half following patient build-up play down the left.
Vokes was now ploughing an increasingly lone furrow for the Clarets, but the Welshman linked up well with Wallace on the hour mark, flicking on a ling kick upfield and firing wide from just inside the area from the Scot’s cut-back.
Burnley clearly needed a spark and Dyche turned to Jamaican sprint-king Richards, who replaced Wallace and immediately won a corner with a burst of pace down the right that livened up the 1,300 visiting fans.
And minutes later, a spring through the middle again caused problems before a last-ditch tackle denied the pint-sized winger a shooting chance.
But disaster struck four minutes from time and despite a later flurry, the Clarets went out of this year’s FA Cup with a whimper.
Burnley: Jensen, Trippier, Lafferty, Duff (Bartley 83), Shackell, Stock, Marney, Treacy, Wallace, Ings, Vokes Subs: Stanislas, Edgar, O’Neill, Fletcher, Grant.
Booked: Stock 25
Sent Off: Stock 37
Barnsley: Steele, Dawson, Cranie, McNulty, Perkins, Golbourne, Kennedy (Cywka 68), O’Brien, Stones, Harewood, Dagnall (Rose 82). Subs: Foster, Etuhu, Lazarus, Hassell, Alnwick.
Booked: Harewood 25
Referee: Paul Tierney
Att: 5,091 (1,396 Burnley)