a 7591 running at +400 is going to pull less than 70 mA before developing plate glow. So, what is creating the heat? I-squared-R in the primary winding? What is primary DCR? Do the calculation, and measure idle current.Is there any other source of heat? you mentioned the rectifier a bit ago.
Have you actually measured temp? 8 seconds is a long time when holding your paws to heat. There is a diff between hot and inducing damage, and hot and able to burn fingers. 85-C is not going to allow 8 seconds of good finger contact, I can assure you...
Still, none of my OPTx's run hotter than I can stand, so I would urge you to discover the heat source.
There is *NO* magic involved, so examine it thoroughly.
cheers,
Douglas
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