Have 24V need 5V 0.1A. Works fine with 78L05 (right size) but gets too hot. Smallest cool alternative ?

Is 100 ohm 1/4 w enough ?

No. And the resistor will burn up.

You need > 2VDC across the 78L05 to regulate, so use 3V drop across it, then the 78L05 dissipates 3V x 0.1A = 0.3W.

Then there is 24V - 5V - 3V = 16V to drop in the resistor.

So 16V / 0.1A = 160 Ohms. There's 16V x 0.1A = 1.6W actual dissipation in the 160 ohm resistor, so use a 3W part.

Use a series 160 ohm 3W resistor. Also use a decoupling capacitor 0.33uF near the regulator.input terminal.
 
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No. And the resistor will burn up.

You need > 2VDC across the 78L05 to regulate, so use 3V drop across it, then the 78L05 dissipates 3V x 0.1A = 0.3W.

Then there is 24V - 5V - 3V = 16V to drop in the resistor.

So 16V / 0.1A = 160 Ohms. There's 16V x 0.1A = 1.6W actual dissipation in the 160 ohm resistor, so use a 3W part.

Use a series 160 ohm 3W resistor. Also use a decoupling capacitor 0.33uF near the regulator.input terminal.
Thanks. 160 ohm - got it.
What does the decoupling capacitor do ?
 
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If the heat from the 3W resistor is a nuisance, you could always use one of these as pre-regulator :

https://www.aliexpress.us/item/3256802944105330.html

I think the max input voltage is 24V though so a couple of IN4001 in series with its input I'd use to stay safe. You'll need the 'adjustable' setting and twiddle the preset pot to give 8V out.
Thanks. But they are gigantic in this respect. Remember the 160E 3W is SMD.
 
You'll find the resistor gets jolly hot doing 1.6W so it'll need plenty space around it.

The 0.33uF is to keep the regulator stable, putting the resistor in line with its feed raises the supply impedance and the decoupler reduces that again at HF.
 
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If you need small, how about these step-down converters designed as drop-in replacement for 78xx:

1668818790985.png


https://www.pololu.com/product/2843
 
I have been looking (on Taobao and Aliexpress) and haven't seen one yet. I guess there isn't a market for TO92 replacement regulators because no heatsink is normally used with them so no need for switchers to replace them. The smallest I'm seeing are TO220 replacements.
 
5V x 0.1A = 0.5W, so the resistor should be able to take at least that much current.
I would use a plain 7805, those are good to 1A, I think, and a 3W resistor.
I have seen BT131 in TO-92, but those are triacs.

Space permitting, or not, use on old cell phone charger, from the Nokia 3315 days, those are good to only about 0.5A, and quite stable. You could discard the housing, and fit the circuit inside your device.

The 24V is for the power amp section of your device?
Unless it is Class D, there should be enough space inside to fit a regular 7805...and ventilation / air flow are always important.
 
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Does your thing have a step down transformer and is one line of the secondary grounded. If so, lift that line and insert a resistor such that it drops about 6vac. Connect that to a diode and filter cap to supply about 8vdc. Such a mod would generate less heat.
Good luck.
 
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How about 78M05 ?

Absolutely fine. I think the M versions were 0.5A and were commonly seen in lots of home entertainment gear like VCR's. They are a T0220 package so perfect.

Also using a series Zener such as a 8v2 1.3 watt type will reduce the voltage the reg sees by 8.2v (so 19-8.2 = 10.8 volts) and that will make the reg run much cooler (even your 78L05). The Zener still gets warm but splits the heat dissipation between the reg and the diode.

Dissipation in the reg falls from 1.4 watts @ 100ma with a 19v supply to just 0.58 watt with the Zener. The Zener gives a more constant input voltage to the reg if the load current varies.
 
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