A extremely compact casing for the Shelly Mini Gen3 for [almost] invisible light switch replacement.
Since I bought the first Shelly 1PM Mini Gen3 I wanted to find a “elegant”-ish /discrete replacement for the manual switch of table top lights and other appliances where the switch is manual and on the power cable itself.
Finally found the time to design to my liking. Hope it helps !
Design:
As COMPACT as possible while staying within what I consider safe (wink wink at your own risk). The switch case is 8 CM x 3.5 CM x 2 CM ! (or +8mm length for ground wago versions)
Reset button and LED Indicator is still accessible/visible from the outside.
Remains ergonomic
No support, so inserts
Cabling is still very easy to do properly and close.
Strain relief is assured by two large zipties on both side of the box (inside). Design space for large ones ans has a ¼ of a circle for easy extraction of the ziptie pointy-bit.
Trade-off is you will need to do 2 soldering… but they are easy and can be done at the very end once all the components are in place.
The compact version has NO GROUND cable WAGO. As most light don't have ground cabling anyway. This is a trade-off for a more compact design. I also provide 2 more version of the case WITH a ground cable WAGO connection included. Alternatively, i'm almost certain you can solder/shrink-tube your way out of this problem.
EDIT: Compatible with both WAGO 221 original and the cheaper copies (larger). Choose your model accordingly.
PRINT:
No Support
0.2mm layers or 0.3mm layers
up to 0.6mm Nozzle is fine
PLA is preferred over PETG, for rigidity
Material Needed:
1x Shelly 1PM Mini Gen3 (other model from the family should fit too)
2x WAGO 221-413
2x small screws. (I used 12mm * 2.5mm with a 5mm head diameter)
2x Large Zipties for strain relief on both ends (inside the box).
1x switch AC rated. Here you will need this one: a "15x21mm AC SWITCH
Rated current is not important as, when used with shelly, the switch does not carry the load nor cuts it (see doc diagram below). Here is one link to find it: Aliexpress but I'm sure it's fairly common. At the time of publishing this model, it's about 1.5€ for 5 of these switches.
To install:
/!\ Disclaimer: I'm not electrician, just a hobbyist, please double check everything on your side regarding the wiring. This is more a “how-I-did-it" guide rather that a “how-to”. That being said:
Insert Shelly and AC Switch in the case
Cut and Strip as indicated in the pictures. At least 9 cm from each side, then use the cut wires to complement the rest of the circuit. You might need more Brown (L) cables.
Do your WAGO wiring directly in the case. (See doc diagram below) I show mine in a picture, please double check properly with manufacturer docs, Especially if you are using another Shelly model. In my pictures:
POWER OUT (to load) is on the side of the Switch - with WAGO L / Brown
POWER IN (from socket) is on the side of the Shelly - with WAGO N / Blue
if you picked a version with ground wago space just add a 221-413 or 221-412 in the available additional slot.
Now that the WAGO wiring is done, insert the WAGOs in their slots as shown in the pictures.
ZIP Tie both cables properly in the only space left in the box. This step is important for strain relief and the design acommodate for easy insertion/extration of the zipties on both side of the box. The ¼ of a circle is designed to help the pointy bit to be fished back out ouf the box. The head of the ziptip should fill the space and touch the box sides.
Unfortunately now it(s time for soldering… Solder the Switch to your circuit. Should be easy and quick. In the picture I show the switch wiring with white cables but you should use AC rated cable here too.
Maybe add some electrical tape on top of your soldering. I did.
Close the case with its lid, should be SNAPPY!, add the 2 screws.
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