A good thermal design should include a solid ground plane, thermal vias under the device, and a heat sink if possible. The datasheet provides some guidelines, but a more detailed application note (SLUA271) is available from TI.
To ensure reliable start-up, make sure the input voltage is within the specified range, the output voltage is not pre-biased, and the soft-start capacitor is properly sized. Also, ensure the input voltage rises monotonically during start-up.
The maximum allowed output capacitance depends on the specific application and output voltage. As a general rule, keep the output capacitance below 100 μF to ensure stability. However, it's recommended to consult with TI's application engineers for specific guidance.
To troubleshoot oscillations, check the PCB layout for noise coupling, ensure the input and output capacitors are properly sized, and verify the feedback loop is properly compensated. Also, check for any signs of component damage or overheating.
A good input filter design should include a common-mode choke, X-capacitors, and Y-capacitors. The specific component values depend on the application and regulatory requirements. Consult TI's application notes (e.g., SLUA369) for more information.