Today I spend some time to detailed analysis of the AIO circuit. If you are following along, I am seeing some issues with light dimming where the Kessil will flickr, this happen only in the AIO circuit, i.e. when the pwm and all other circuit (ato, temperature, relay) are wired together. This does not happen when I use the Kessil controller independently. So, today I spend some time hooking up everything with a bread board and looking at signals at different hops, in different combinations of circuits. As expected , I noticed that the pwm signal has noise, particularly when used with lm2596 modules. In AIO circuit, if I power the Pi & pca9685 with an independent 5v power supply (such as the micro usb ones) thing run smooth.
Here is a screen shot of the oscilloscope when everything uses a single power supply (i.e. a single 12v supply, then step down to 10v and 5v by two lmm2595 modules)
Generated pwm signal. For refrence, pwm signals are square waves , hence the up and down. The amount of UP is equivalent to percentage dimming. Notice the spikes present in both up as well as down part of the signal
And this is the signal when I use a dedicated 5v power supply for pi/pca9685. Then the signal is much more stable, without the spikes.
I could reproduce this with both Pi based PWM as well as pca9685 based pwm.
I am reading and thinking about what should be my next step. Whether to throw in capacitors (i have to decide the value and the exact location in circuit) or use some other power regulator modules to power the AIO circuits... will keep you all posted. Whatever happens, this is a good data that i can share while discussing the problem with others more knowledgeable than me :)