SGBRU-61-400-4 Braking Unit – Essential VFD Drive Panel Accessory
Brand name: HANI
Packing Details : Wooden box with fumigation or Wooden Fram or Steel Frame
Delivery Details: 30~60days or Based on the quantity
Shipping: Sea freight、Land freight、Air freight
HANI specializes in industrial electrical automation, delivering integrated drive and control solutions to safeguard your production.
Product Details
SGBRU-61-400-4 Braking Unit – Essential VFD Drive Panel Accessory
In modern industrial automation products, the ability to safely and rapidly decelerate high-inertia loads defines process reliability. The SGBRU-61-400-4 Braking Unit from HANI is a robust VFD accessory designed specifically for AC380V variable frequency drive systems. It converts the regenerated kinetic energy of a motor into thermal energy via an external resistor, delivering true dynamic braking where uncontrolled overvoltage would otherwise trip the drive. For panel builders and system integrators seeking certified industrial automation products, this braking unit offers field-proven overload margins, digital configurability, and a compact IP20 footprint.
How dynamic braking works in VFD systems
When a variable frequency drive decelerates a motor, the motor temporarily becomes a generator, pumping energy back onto the DC bus. Without a braking unit, the bus voltage rises until the drive’s overvoltage protection halts operation. A dynamic braking solution monitors the DC link and, at a preset threshold, switches an external power resistor across the bus. The SGBRU-61-400-4 contains a high-speed IGBT chopper that precisely regulates the braking current, maintaining the DC bus within safe limits. This is a foundational technology across countless industrial automation products, from crane controls to high-speed spindles.
SGBRU-61-400-4: core specifications
The SGBRU-61-400-4 is rated for a maximum braking current of 400 A and is built for AC380 V power systems, corresponding to a DC bus range of 460 V to 800 V. As part of HANI’s family of industrial automation products, it is classified as a heavy-duty braking unit with an initial braking torque setting of 100% (adjustable from 10% to 100%). The table below summarises the single-unit and parallel-unit configurations as documented in the manufacturer’s selection guide.
| Braking Unit Model | Max Braking Current (A) | Paralleled Units | Adapted VFD Power (kW) | 100% Torque Braking Resistor (Ω) | Resistor Dissipation P20 (kW) | Min. Braking Resistor (Ω) |
|---|---|---|---|---|---|---|
| SGBRU-61-400-4 | 400 | 1 | 220 | 2.2 | 33 | 1.8 |
| SGBRU-61-400-4 | 400 | 1 | 250 | 2.0 | 38 | 1.8 |
| SGBRU-61-400-4 (2×) | 2 × 400 | 2 | 500 | 2.0 × 2 | 38 × 2 | 1.8 × 2 |
* Resistor values are calculated for 100% braking torque at the rated VFD power. The minimum braking resistor column indicates the lowest permissible ohmic value to protect the IGBT chopper. For tailored resistor selection, consult HANI’s comprehensive guide covering these industrial automation products.
General technical specifications
| Parameter | Specification |
|---|---|
| Supply / DC bus voltage | AC380 V supply → DC 460 V – 800 V |
| Braking unit type | Heavy-duty, initial braking rate 100% (adjustable 10 %–100 %) |
| Heatsink overheat protection | Temperature > +80 °C → fault relay |
| Fault output relay | 250 V AC / 3 A, 30 V DC / 1 A |
| Cooling fan control | Fan starts when module temperature > +40 °C |
| DC+/− cable length | Total length < 5 m |
| Resistor cable length | Total length < 10 m |
| Operating panel | Brake start/stop voltage threshold, braking rate 10 %–100 %, fault/alarm display |
| Ambient temperature | −15 °C to +40 °C (no frost) |
| Storage temperature | −20 °C to +60 °C |
| Humidity | < 95 % RH, no condensation |
| Vibration | < 5.9 m/s² (0.6 g) |
| Enclosure | Wall-mount IP20, cables entry/exit from bottom |
Overload capability and duty cycle
The SGBRU-61-400-4 Braking Unit is engineered for demanding dynamic braking cycles. Based on the manufacturer’s time-current profile, the unit tolerates a continuous brake current of 100% rated (400 A), with a surge capability of 150% rated current (600 A) for up to 5 seconds, after which it reverts to 100% continuous. In practical terms, a 300-second cycle may include a 5-second 150% burst followed by 100% continuous current. This headroom is crucial in industrial automation products where abrupt deceleration of a loaded conveyor or a centrifuge creates a regenerative power spike. Proper thermal sizing ensures the internal IGBT and freewheeling diodes remain within safe junction temperatures even under repetitive heavy-duty stops.
Operator panel and threshold configuration
A built-in digital panel distinguishes the SGBRU series from basic chopper modules. Users can independently set the brake start voltage and brake stop voltage to match the DC bus characteristics of the connected VFD. The braking rate is continuously adjustable from 10 % to 100 %, allowing fine-tuning of the deceleration ramp without oversizing the resistor. Alarm and fault codes are displayed locally, enabling immediate diagnostics. Such intelligent features elevate this Braking Unit among comparable industrial automation products, reducing commissioning time and preventing nuisance trips.
Installation and wiring best practices
Maintain the total length of the DC link cables (DC+ and DC−) between the VFD and the SGBRU-61-400-4 below 5 metres. The connection between the braking unit and the external resistor must not exceed 10 metres. Twisted or closely routed cable pairs minimise parasitic inductance, which is essential for preserving the IGBT switching performance in dynamic braking circuits. The built-in temperature-controlled fan activates when the module temperature surpasses 40 °C; ensure at least 150 mm of free space above and below the unit for adequate convection. When integrating this VFD accessory into a panel, always follow the local regulations for short-circuit protection and emergency stop circuits—HANI provides detailed wiring diagrams for all its industrial automation products.
Model number breakdown
| Code | Meaning |
|---|---|
| SGBRU | Product name: Braking Unit |
| 61 | Series designation |
| 400 | Maximum braking current: 400 A |
| 4 | Voltage class: 4 = AC380 V system (DC460–800 V); 7 = AC690 V system (DC850–1200 V) |
Parallel operation for higher power
When the motor power exceeds 250 kW, two SGBRU-61-400-4 units can be paralleled to deliver 800 A combined braking current. The selection table shows a dual-unit configuration supporting up to 500 kW with a 2.0 Ω resistor bank rated at 76 kW P20. Proper current sharing is managed by the chopper synchronisation circuits inside each braking unit. This modular scalability makes the SGBRU-61 family an ideal VFD accessory for large-scale industrial automation products such as mine hoists and marine propulsion test benches.
Frequently Asked Questions
Q1: How do I select the correct braking resistor for the SGBRU-61-400-4?
Choose a resistor value equal to or slightly higher than the “100% Torque Braking Resistor” column for your VFD power, but never below the “Minimum Braking Resistor” value. For a 220 kW drive the recommended value is 2.2 Ω with a dissipation rating of at least 33 kW (P20). Using a lower resistance may trigger the unit’s overcurrent protection and damage the IGBT. HANI’s catalog of industrial automation products includes matching resistor banks pre-calculated for all SGBRU models.
Q2: Can the SGBRU-61-400-4 be used with 690 V drives?
No. The “-4” suffix designates an AC380 V system with a DC bus of 460–800 V. For 690 V VFDs, choose the SGBRU-61-xxx-7 variant, which operates on a DC bus of 850–1200 V. Mismatching the voltage class will cause immediate fault or destruction of the braking unit.
Q3: What does the braking rate setting actually control?
It sets the maximum PWM duty cycle applied to the braking IGBT, effectively limiting the average braking current. At 100 % braking rate the chopper can deliver the full rated current continuously (subject to thermal limits). Reducing the rate extends the deceleration time but lowers the peak power dissipated by the resistor, which is often helpful when retrofitting existing VFD accessory installations.
Q4: What is the expected service life of the internal fan?
The fan is a long-life ball-bearing type rated for approximately 70,000 hours at 40 °C. Because the fan only operates when the module temperature exceeds 40 °C, its actual service life in typical cyclic dynamic braking applications can exceed 10 years. The fan assembly is field-replaceable; HANI supplies spares as part of its commitment to sustainable industrial automation products.
Q5: Can I mount the SGBRU-61-400-4 side-by-side with other equipment?
Yes, provided the ambient temperature stays below +40 °C and there is no restriction to vertical airflow. Maintain at least 150 mm clearance above and below the unit. When multiple braking units are installed in the same cabinet, ensure the total heat load is accounted for in the enclosure climate control design. For guidance on integrating this VFD accessory into larger systems, refer to HANI’s panel design handbook for industrial automation products.
Q6: Is a separate power supply required for the control electronics?
No. The control board and operator panel are powered directly from the DC bus. As soon as the VFD’s DC link is energised, the SGBRU-61-400-4 is active and ready for dynamic braking. This simplifies wiring and reduces the number of external components in the drive panel.
Typical application scenarios
- Overhead cranes and hoists: Controlled lowering of heavy loads requires continuous dynamic braking to dissipate potential energy. The SGBRU-61-400-4 handles the sustained regenerated currents typical of such industrial automation products.
- High-inertia centrifuges: Rapid deceleration of a centrifuge bowl from high speed demands a braking unit with substantial overload margin—exactly the 150 %/5 s capability this model provides.
- Machine tool spindles: Quick tool changes and emergency stops rely on this VFD accessory to halt spindles within milliseconds without overvoltage faults.
- Test benches and dynamometers: Where motors under test are driven as generators, the SGBRU-61-400-4 serves as a reliable energy dump, safeguarding the entire chain of connected industrial automation products.
- Escalators and people movers: Regenerative braking during downward operation is managed safely, preventing heat build-up in the drive.
Integration with HANI’s ecosystem of industrial automation products
HANI’s SGBRU series is not an isolated component; it is designed to interface seamlessly with the company’s range of VFDs, line reactors, and output filters. When combined, these industrial automation products form a tested and certified drive system that simplifies EMC compliance, thermal management, and after-sales support. For panel shops, specifying a single brand for the drive and the braking unit eliminates compatibility guesswork and streamlines commissioning. HANI provides pre-configured parameter sets for its VFDs that recognise the SGBRU-61-400-4 automatically, adjusting the DC-bus voltage thresholds and fault handling to suit the characteristics of this heavy-duty dynamic braking chopper.
Reliability and compliance
Every SGBRU-61-400-4 undergoes a full-load burn-in test at the factory, with the internal IGBT module temperature cycled to verify thermal interface integrity. The IP20 metal enclosure is built for wall mounting, with bottom cable entry that promotes clean cable management inside the drive panel. As with all HANI industrial automation products, the braking unit is CE-marked and meets the relevant IEC 61800-5-1 safety requirements. The fault relay output provides a volt-free contact that can be wired into the site’s safety PLC or emergency stop loop, adding a layer of protection beyond the basic VFD alarm.
For detailed application engineering support or to request a quotation for the SGBRU-61-400-4 Braking Unit and associated resistors, contact HANI’s technical sales team. HANI continues to expand its portfolio of industrial automation products with reliable, well-documented VFD accessories that help system integrators deliver safer and more efficient machinery.
HANI is one of China’s leading professional industrial electrical automation manufacturers, providing complete drive and control solutions to customers worldwide. HANI focuses on designing and manufacturing integrated automation systems that meet the industry’s highest standards of precision, efficiency, and durability. Our engineering expertise lies in providing turnkey electrical automation projects to optimize the performance of modern industrial manufacturing plants.
