Pluggable Housing with Schuko-Connectors for Shelly PM mini Gen3

Preamble

Please regard the following informations as my report of a solution to re-use the Shelly PM mini Gen3 devices as pluggable energymeter.
Use the provided models and described procedures completely at your own risk and at your own responsibility.

Motivation

I bought several Shelly PM mini Gen3 devices to monitor various electrical units in my household.
Unfortunately I had to find out, that the space available in the mains outlets was not sufficient to properly assemble the devices in the existing mains supply circuits.

Well, there are pluggable devices available, but I didn't want to buy the same thing twice.
Scrapping also was not an option for me.

Solution

Therefore I designed a housing with Schuko-plug and Schuko-outlet to incorporate the already purchased Shelly PM mini Gen3 devices, so I would be able to use them as originally intended.
To allow good connections, I integrated a WAGO221-413 splicing connector with levers to make sure a safe and reliable wiring can be realized.
Visibility of the Shelly-status-LED and safe operability of the Shelly device button with locked housing also were realized.
As an option, the housing can additionally be sealed with a 1mm silicone foam string placed in the groove of the lid before screwing in the M3 screws to fasten the lid.

Print

The material recommended is PETG or PC
                (The used material must not contain any electrically conductive additives 
                  like carbon fibers, metal, etc. !)
 The material must also provide sufficient mechanical properties.), as during usage the holders have to keep the Schuko outlet in position and must support the mechanical strength for cable and normal mechanical stress on the housing during usage...

Printed with SUNLU PETG (Black).

  [ Housing parts]
  1x Housing base    = SPMM_ConnectorHousing_base_v01.stl
  1x Housing lid        = SPMM_ConnectorHousing_lid_v01.stl

     (support:                  recommended)
     (brim:                       not always needed (depending on sheet: smooth, satin -> no brim / textured -> brim)
     (print orientation:   bottom face (closed) down)
     (colour:                    Any colour you like ;-)

Warning

Attention - mains voltage - potential life hazard:

• The assembly and functional checks must only be performed by a skilled electrician.
  (Don't do anything unless you really know what you are doing!)
  As the device is used between mains socket and the measured electrical device,
  the correct wiring (especially PE/ protective earth) must be guaranteed to avoid 
  potentially hazardous situations.
  Before operating the device, it must be checked by a skilled electrician to ensure safe operation.
  

• During assembly the device allows access to contacts and wiring with mains voltage (230 V~) 
  → Potential risk of electric shock
  Always keep the device disconnected from mains power while working on it.
  NEVER plug the device into mains before completely and securely closing the housing.
  Make sure the device cannot be plugged into mains accidentaly while the housing is open.
  

• Keep any electrical parts used for the device out of reach of children
  → Potential risk of electric shock
   

• Unplug the device from mains immediately when you detect a broken housing
  Make sure children and other persons unaware of the damage and the related risk do not have access to the damaged part … keep it in a safe place.
   

• Unplug the device from mains plug before taking any actions for disassembly.
   

• For your own safety: Electrical safety regulations have to be obeyed.
   

• Only operate the device within the specifications listed for the components used:
  Shelly PM mini Gen3:   max. 16 A at 240 V AC
   

• Any use and operation  of the device is  done at your own risk and responsibility.

Assembly

Parts list:
  1x housing base (SPMM_ConnectorHousing_base_v01.stl)
  1x housing lid (SPMM_ConnectorHousing_lid_v01.stl)
  1x Shelly PM mini Gen3
  1x WAGO221-413
       (https://www.amazon.de/-/en/dp/B00JB3U9CG?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_3&th=1)
  1x Schuko socket
       (https://www.amazon.de/dp/B086K7HB9N?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1)
  1x M16 Cable Gland
  1x Schuko plug with 3x1.5mm² extension lead (0.5m)
       (https://www.amazon.de/dp/B0H35F8NDK?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1)
       Hint/learning: An angled Schuko plug saves space when installing the power meter.
  4x M4x12 countersunk hex screws
  4x M4 nut
  4x M3x10 cylinder screws, hexagonal button
  3x Flexible Single Wire Cable H07V-K 1.5 mm² (2x 10cm blue, 1x7cm black, ends secured with ferrules)
       (https://www.amazon.de/-/en/EBROM-Flexible-Single-H07V-K-Colour/dp/B077JZNWV7/ref=sr_1_6?crid=9LWG9YX4R7J6&dib=eyJ2IjoiMSJ9.JB2-UqgRjyKdJmzfcQkJdXWNDEZvlWNyaBa-Ok54--oOkrF1obwgKW_E5Y6iQmpnCT1zKluddmux67VSSwu5Mvm2zRiMDan7bgKX0F_XHEsEKwdLbv1dtP9EqngJktiBUETAKlh9A-3_c7dyM1thYL4m6fVFLDHy4kjL-HMYeVyCHBSKv-wpXpNCvwiTqgsL8L03p2t_qABS856GcZrLxkqQGowd0GfIXjT4lMMosxlufNKQUz4IXrOcuc-yChrT.Jj1g0z85m1WV_0OiUGYTZsn_fU-LtrJ1JC4WRd_wxx0&dib_tag=se&keywords=schaltlizze%2B1.5mm%C2%B2&qid=1792447200&sprefix=schaltlizze%2B1.5mm%2B%2Caps%2C165&sr=8-6&th=1)

[Step 1] Schuko-socket
  1x housing base
  1x Schuko socket
  4x M4x12 countersunk hex screws
  4x M4 nut
Assemble the Schuko-socket into the housing base using M4 countersunk screws and nuts.

[Step 2] Shelly PM mini Gen3 + WAGO splicing connector with levers
  1x Shelly PM mini Gen3
  1x WAGO221-413 splicing connector
Firmly clip the WAGO splicing connector into position (openings and levers facing upwards).
You should her a clear snap when the connector locks in its proper position.

Next push the Shelly PM mini Gen3 into its holder. Make sure the contact screws are accessable.
LED indicator and button face outwards (openings are available in the housing)

[Step 3] M16 Cable Gland + Schuko Plug
  1x M16 Cable Gland
  1x Schuko plug with 3x1.5mm² extension lead (0.5m)
Remove the secondary insulation so the open wire ends are long enough for connecting them properly.
Make sure the open wire ends are secured with ferrules to avoid splicing (don't use solder here).
Assemble the cable gland into the housing base and tighten the nut firmly.
Push the cable through the gland until the secondary insulation visibly reaches into the housing.
Make sure the open wire ends reach far enough into the housing for later connection.
Firmly tighten the glsnd so the cable cannot slip out again.
Test by firmly pulling the cable.

[Step 4] Wiring
  2x Flexible Single Wire Cable H07V-K 1.5 mm² (2x 10cm blue, ends secured with ferrules)
  1x Flexible Single Wire Cable H07V-K 1.5 mm² (1x7cm black, ends secured with ferrules)
Connect the PE (protective earth) wire of the Schuko plug wire directly to the Schuko-socket.
Connect L (black) and N (blue) wires according to the image.
The (bare) 12mm ferrules ave to go into the WAGO connector in full length before colsing the lever.
Make sure all screws are tightened firmly and no uninsulated wire ends are accessible.
(For the Shelly connector I had to shorten the ferrules a little to be able to push them into the connectors in full length.

All checks are done with the device unplugged!!!
a) check all connections mechanically for a firm lock.
b) make sure that all connections ar correct (according to wiring scheme / compare to image above)
c) check all connections with a multimeter

[Step 5] Close housing
  1x Housing lid 
  4x M3x10 cylinder screws, hexagonal button
optional:
  34cm of  silicone foam string (1mm diameter) as sealing

Place the silicone foam string into the groove in the housing lid and cut to appropriate length (no overlap).
Firmly secure the lid on the housing base and fasten all 4 screws firmly (avoid excessive forces in order not to damage the housing base screw domes).
 

[Step 6] TEST (important before use)
Electrically test the device with a suitable testing device BEFORE operating it with a connected appliance.

Never use the device without being 100%sure about technical reliability and electrical safety.

[Step 7] Configure PM mini Gen3
(This actually is a no-brainer...)
To be able to access the Shelly PM mini Gen3 readings, you first  need to configure and integrate the connected device into your Smart Home environment.

Have fun using the device!

Feedback, suggestions and criticism are welcome ... I always like to improve my designs.