I don't know if this will help, but I had something like this on a clock I 
was prototyping. The error I had was that the MOSFET was sometimes being 
left in the ON state for longer than I expected sometimes. 

Once the inductor has "saturated", you effectively have a short from VIN to 
GND, and of course the MOSFET gets hot when that happens, and the 
consumption goes right up. This can happen if the frequency of the drive is 
too low, or the duty cycle is wrong (too much "on" time).

Have you investigated the frequency and duty cycle of the output of the 
TL494?

>From the schematic, it looks like the frequency is fixed (at around 18kHz), 
and the voltage output is controlled by the duty cycle. I have no idea what 
the time constant of the inductor circuit will be, but after 5 of them, you 
are in dead short.

Just a thought...



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