Description
Product Introduction
The Reliance Electric 805405-1R is an internal DC Field Power Module designed for integration within FlexPak 3000 and MaxPak III industrial DC drive chassis. Built for demanding heavy-industry motor control, this regulator assembly regulates incoming AC line power to deliver controlled DC field excitation for shunt-wound and compound DC motors.
Unlike generic external field supplies that lack integration with drive diagnostics, the 805405-1R interfaces directly with the drive’s main control board. It enables automatic field weakening, field economy modes, and instantaneous field-loss protection to safeguard motor windings against destructive overspeed conditions.
Key Technical Specifications
| Parameter | Value / Specification |
| Manufacturer | Reliance Electric / Rockwell Automation |
| Assembly Number | 805405-1R |
| Associated PC Board | C-058019-F (or equivalent revision) |
| Input Voltage Rating | 230 – 460 VAC (3-Phase / Single-Phase depending on tap) |
| Input Frequency | 50 / 60 Hz |
| Output Voltage Rating | Up to 500 VDC |
| Max Continuous Current | 15 A DC |
| Drive Compatibility | FlexPak 3000, MaxPak III, DC Regulatory Assemblies |
| Cooling | Convection / Chassis Fan Airflow |
| Operating Temperature | 0°C to +55°C (32°F to +131°F) |
Application Scenarios & The “Trench” Experience
Picture this: It’s 2 AM on a cold winter night in a steel rolling mill. A heavy 250 HP DC motor driving a main stand coiler trips out instantly on a “Field Loss” fault. The motor field current drops to zero, the drive refuses to reset, and steel rod stock is piling up ahead of the shear. The original regulator board shows scorched snubbers due to line surge transients.
In our field experience, having a bench-tested Reliance Electric 805405-1R module on your spare parts rack is the difference between a quick 30-minute swap and a multi-shift shutdown. Drop the replacement board into the drive bay, secure the heavy-gauge spade connections, verify line voltage taps, and get the mill rolling again.
- Metal Processing & Steel Mills – Main drive coiler and uncoiler field excitation – Maintains stable torque profiling during acceleration and field weakening.
- Paper & Pulp Converting – Sectional paper machine DC drives – Delivers tight field current regulation to prevent web break tension spikes.
- Extruders & Rubber Mixers – High-torque DC motor drive systems – Protects field windings from thermal overload during continuous duty.
- Crane & Hoist Systems – Heavy-lift DC motor drives – Ensures positive motor field generation before mechanical brake release.
805405-1R
805405-1R
Transparency SOP: Quality Assurance & Testing
We don’t just ship boxes; we test them on actual Reliance Electric drive rigs. Here is how we verify every 805405-1R module before it leaves our facility:
- Inbound Visual & Component Inspection: Inspect power SCRs/diodes, trace health, terminal blocks, check for thermal stress, and verify original Reliance manufacturing labels.
- Cold Semiconductor Meter Checks: Perform junction resistance and diode drops on onboard thyristors and rectifiers to ensure zero shorted components.
- Chassis Integration & Power-On Test: Mount the module into a live FlexPak 3000 test drive to verify backplane ribbon handshakes and control power rail distribution.
- Dynamometer Field Load Testing: Connect the module output to an actual DC motor field winding and sweep field current commands up to 15 A to confirm regulation stability.
- Final Clean & ESD Packaging: Treat edge connections and power terminals with contact restorer, then seal the unit inside static-shielded packaging with fresh desiccant.
The Veteran’s Tech Trap Guide (Crucial Value-Add)
- ⚠️ Never Fire Up Without Checking the Motor Field Resistance First! If the original 805405-1R board blew out, measure the DC motor field winding resistance before installing the replacement. A shorted field winding will instantly destroy the SCR power bridge on your new module.
- ❗ Verify Voltage Tap Jumpers: Ensure the incoming voltage taps and jumpers match your plant line voltage (230V vs 460V). Applying 460V to a board configured for 230V will blow the onboard MOV surge absorbers and line fuses instantly.
- ⚠️ Tighten High-Current Screw Terminals Properly: Field terminals carry up to 15 A continuous DC current. Loose screw terminations create high-resistance hot spots that char terminal housing plastic and cause intermittent field loss trips.
- ❗ Document Drive Parameter Settings: After replacing the board, check drive parameters related to minimum/maximum field current, field economy delay, and field weakening thresholds. If the drive main board lost memory, these settings must be re-entered. Trust me.
Frequently Asked Questions (FAQ for Conversion)
Q: Is the Reliance 805405-1R hot-swappable inside a FlexPak 3000 drive?
A: No. Absolutely isolate all main 3-phase AC power and 115V control supplies to the drive chassis before servicing internal power modules to avoid severe shock hazards.
Q: Can I use this board for motors requiring more than 15 Amps of field current?
A: No. The 805405-1R is rated for a maximum continuous current of 15 A DC. For larger DC motors requiring higher field current, an external high-current field regulator assembly must be used.
Q: What is the difference between the 805405-1R and older revision boards?
A: The -1R suffix designates a specific revision assembly incorporating updated snubber components and board layout improvements for better transient voltage suppression.
Q: What warranty coverage comes with this module?
A: We back all New Surplus and Refurbished Reliance Electric modules with a complete 12-month replacement warranty from the invoice date.
Q: Why buy surplus Reliance Electric parts instead of ordering factory new?
A: Reliance Electric legacy DC drive hardware is obsolete and no longer produced by the OEM. Sourcing fully bench-tested surplus modules is the fastest way to keep legacy plant equipment running without undergoing an expensive drive retrofitting project.
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