Is your transformer (inductor) getting too warm ? It's possible that the 
peak current is larger than Isat; at saturation the magnetic efficiency 
drops way off.

It's not easy to measure the inductor current, because parasitics are 
introduced by the scope-probe. Most often, the ground lead picks-up noise 
and makes your signal look far worse than it really is. I remove the ground 
clip and the plastic shroud around the probe tip. Then, I wrap a few turns 
of bare wire around the exposed ground of the probe (approx 1-2 mm from the 
probe tip) and solder that to the closest GND connection. This minimizes 
the coupling of noise to the scope's ground; I've actually removed several 
volts worth of noise using this technique. This will allow you to view 
clean *voltage* waveforms.

If you dont have an expensive current probe (I certainly dont), you will 
need to insert a small resistance (100 milliohms) and measure the voltage 
across it to infer current. Make sure it is NOT a wirewound resistor, which 
is inductive.

The current waveform should look triangular (increase linearly from 0 to 
peak when the switch is on, then decrease to 0 rapidly when the switch 
turns off). Once you have that you can start debugging where things are 
going wrong.


Converters always seem to run beautifully with no-load; when you start 
loading them down, all kinds of things happen.

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