The PRS-505 has a 300K limit on the individual text file sizes of an ePub document. Maybe the original ePub had one or more files larger than this (you can check looking inside the original ePub with 7-zip or any other compression program).
When you converted to LRF that problem disappeared.
I don't know what you used to convert back to ePub. Calibre, for example, when converting to ePub for use in Sony readers, splits the text so that the 300K limit is not exceeded.
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