On Thursday, 9 October 2014 14:37:26 UTC+1, M.J.Sangster wrote:
>
> My guess is the heat is coming from the 7805 - they tend to generate heat 
> with even modest current draw. I believe a simple linear voltage regulator 
> is around 40% efficient - the rest goes to heat. The circuit uses 2 74141 
> type IC's, they draw a lot of current. If it was a problem (too much heat) 
> the regulator would shutdown.
>
> The power supply looks good, I'm guessing neither the FET or the inductor 
> even get warm.
>

The 74141s take 25mA each - being generous, the whole circuit may take 70mA 
including the alarm and GPS LEDs - the CPU is an ultra-low-power one and 
almost everything else is driven from the 12V rail - with 12V in, 5V out 
that's a 7V drop in the 7805 @ 70mA which is only about 500mW of heat - a 
7805 in a TO-220 case hast a theta JA of 19C/W so the case will get to 
maybe 10C above ambient (perhaps a bit more as its in a case), i.e. its 
unlikely to get very hot at all (unless its oscillating, but it does have 
input and output 100n ceramics).

Nick

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