Nick,

Would replacing the 7805 with a 'non-isolated dc/dc converter' like Jon 
suggested solve the problem too?  I ask because I was going to try the 
Traco TSR 1-2450, or the Murata part (though I'm not sure it will fit.)  I 
ordered both.

I'll get my scope out today and see what I can see.

Kiran

On Monday, March 30, 2015 at 6:33:57 AM UTC-4, Nick wrote:
>
> Just to re-iterate - solder a small 100nF capacitor between pins 1 & 2, 
> and another between pins 3 & 2, preferably on the underside of the PCB 
> directly to the 7805's solder pads.
>
> The symptoms you are seeing are almost certainly nothing to do with the 
> heatsinks etc - I'd put good money on this being a very common & classic 
> issue with 78xx & 79xx linear regulators whereby they break into VHF 
> oscillation and over-heat. This is extremely well documented and the 
> manufacturer's datasheets all say that the two suppression caps are not a 
> "nice to have" but are essential. Most of the datasheets actually specify a 
> 330nF input capacitor (between pins 1 & 2) but a 100nF works well too.
>
> Missing out these two capacitors is a basic error.
>
> Nick
>
>

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