Messana mZone User manual

messana zone

mZone, the controller that conveys comfort and energy where and when needed
Messana mZone delivers a uniform comfort level thorough your living space.

designed in California & made in Italy
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Programmable zone controller
mZone is a fully programmable zone controller available in two different sizes: 8 and 12 zones.
It is integrated with the Messana climate control platform developed with more then 20 years of experience in
radiant cooling and heating technology. It connects with mBox via Ethernet or, alternatively, via serial bus (RS485
slave) and it interfaces with the Messana web and mobile App.
mZone is powered with a dedicated Emerson programmable I/O module based on a high performance 32-bit ARM9
(200 MHz) microprocessor.
mZone integrates a 24Vdc switching power supply (120-230 Vac with 85W output power for mZone 8 and 120W for
mZone 12) and does not require an external transformer to drive thermal actuators. With a proprietary staggered
activation technology it can drive up to 34 thermal actuators (with mZone 12)
The mZone module connects up to twelve mSense room sensors (mZone 12) or up to eight mSense (mZone 8) in
daisy-chain via serial bus (RS485 master zone bus).
mZone modules are typically installed next to the manifolds to control the flow or the radiant fluid by activating the
thermal actuators installed on the manifold loops or the zone valves.
mZone can also control a local mixing and pumping station with a PID close control loop.
Based on the current supply fluid temperature, mZone adjusts the position of a proportional 3-way mixing valve
and modulate the fluid temperature. Compared to a traditional On/Off control, this technology allows to deliver just
enough heat (or cool, by heat extraction) to avoid temperature swings and oscillations.
With the PID control logic the radiant system always achieves optimized performance in terms of energy efficiency
and comfort maintaining an accurate and uniform indoor temperature.
mZone is designed for 2-pipe as well as for 4-pipe distribution systems for simultaneous heating and cooling
demand. Can also control heating and cooling seasonal changeover (manually or following a schedule) or
automatic changeover based on the internal load and external conditions (adaptive-comfort).
It works also with hybrid radiant/forced-air cooling and heating systems. Can activate fan-coils when supplemental
convective integration is necessary.
One of the features that distinguishes the mZone controller, compared to similar products available on the market,
is the vast range of both analog and digital input/outputs ports to connect with external devices. Most of the I/Os
are fully configurable and are opto-insulated.
As an optional, mZone can be equipped with a graphic display that allows reading of all the parameters (supply
and return temperature, flow and pressure, zone status, zone temperature and humidity) and to perform manual
installation test (pump and zone activations, force zone on or off, mixing valve setup).
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Making control simple and powerful
Controlled by mBox
mZone connects to mBox (via
Ethernet or serial bus RS485).
mBox is the brain of any Messana
climate control platform. It is
based on a Linux embedded
system and it operates advanced
radiant cooling logics.
WAGO CAGE-CLAMP®
WAGO terminal blocks with
CAGE CLAMP® connection
technology. It makes connections
to the mZone safe, quick and
easy. It requires a small screw
driver to open the clamp and the
wire (strained or solid conductor)
is inserted in the clamp.
Connect with mSense
mZone controls up to 8
(mZone8) or 12 (mZone 12)
different zones. Each zone
is monitored with the new
Messana mSense room comfort
sensor that measures operative
temperature, relative humidity,
and indoor air quality.
Graphic display (optional)
mZone can be equipped with
a graphic display to show I/O
status and allow the operator
to troubleshoot the system and
perform basic tests on thermal
actuator, pumps, mix valve,
actuators etc.
Powered by Emerson
mZone modules are powered
by a dedicated Emerson
programmable I/O controller.
Emerson is the world’s leading
provider of HVAC control
solutions for residential, and
commercial applications.
Opto-insulated I/Os
Opto-isolators provide a safe
interface to protect internal
circuits from excessive or
transient voltage spikes that
could potentially damage the
device.
PID temperature control
mZone can control one or two
mix/pump stations. With a
PID (Proportional Integrative
Derivative) control logic, it
modulates the fluid temperature
to optimize comfort and energy.
Programmable analog I/Os
Programmable I/Os allow to
integrate with different types
of hvac devices. Analog inputs
are configurable as NTC, PTC,
0-20mA, 4-20mA, 0-10V, 0-5V,
0-1V, or DI. Analog outputs can
be set as 0-10V or 4-20mA.
PID
Staggered activation
Messana has developed an
optimization algorithm that
stagger the opening of thermal
actuators to minimize the
maximum current rush. This
technology allows to increase
the number thermal actuators
(up to 34 with mZone 12).
BOX

110/220Vac
50/60Hz
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PID
Control Logic Rooms Temperature
S
R
Radiant
Panel
Heat
0-10V
 T
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mZone can dynamically modulate the fluid supply temperature when is combined with an hydronic mixing and
pumping station.
The mixing station features a high efficiency recirculating pumps, a motorized 3-way proportional mixing valve
(0-10V or 2-10V) and two temperature probes installed on the supply (S) and return pipes (R). This configuration
allows to a PID (Proportional Integrative Derivative) control loop with temperature feedback mechanism.
PID Control Logic Schematic
Messana PID temperature control logic

Time
Temp
Set-point 72
OFF ON OFF ON OFF ON OFF ON OFF ON
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF
Legend
PID
ON / OFF Control
OFF ON
71
73
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The Messana PID control logic evaluates the supply temperature (target ) based on how far is each zone from the
desired set-point (proportional), how long is in that status (integrative) and how quick the radiant terminals reacts
to the fluid temperature change (derivative). This technology allows to deliver just enough heat (or cool, by heat
extraction) to always meet the actual internal loads and maintain the correct room operative temperature within a
0.5F differential.
With the PID control logic the radiant system achieves optimized performance in terms of energy efficiency and
comfort maintaining always an accurate and uniform indoor temperature.
The PID control logic regulates the supply water temperature, and ultimately the room temperature, based on the
three different actions:
Actions Based on
Proportional The actual value of the room temperature
Integral The past values of the room temperature
Derivative The expected variation of the room temperature

Power pick optimization note 1
Time
Power pick is reduced by 40%
Power
7.2W x N/2
6W x N
1W x N/2
Start 2 minutes
Legend
Staggered activation with two groups of actuators each
Normal activation
NIs the total number of thermal actuators
6W x N/2
Power pick (6W x N)
2W x N/2
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The Messana thermal actuators are based on a PTC resistor-heated elastic element and a return compression
spring. When the elastic element is heated by applying the 24V voltage to the PTC resistor, it expands and moves an
integrated plunger to open the valve. When the PTC resistor stop being energized, the elastic element shrinks and
the return compression spring moves the plunge back and close the valve.
During the activation of the actuator there is an initial phase of about 2 minutes where more heat is necessary to
expand the elastic element. During this initial phase the current spikes up to 6 times the nominal current needed to
hold the actuator activated. This initial high load (6 Watts per actuator) limits the number of thermal actuators that
can be activated simultaneously based on the total available power supply. Once the actuator is open, the elastic
element needs to be maintained hot and this requires only 1 Watt per actuator (nominal power).
When sizing the power supply of zoning module, in order to satisfy the initial rush current needed to open
simultaneously all the actuators, it requires 6W x N (total number of actuators). With the intent of optimizing
the maximum number of actuators that can be driven by one mZone module, Messana has developed a new
technology that staggers the activation of actuators and avoid the initial load pick. It is a group delay mechanism
that prevents to turn on multiple actuators at the same time to prevent power surge. The actuators attached to the
mZone are divided in two groups of N/2 actuators each.
The staggered activation logic activates the first group of actuators (group #1) and wait until they complete the
initial opening phase (about 2 minutes). Once the first group of actuators is partially open, and the power has
dropped close to its nominal value (1W x N/2), the logic starts the activation of the second group of actuators
(group #2).
With an overall delay of 2 minutes, the staggered activation logic can operate two distinct groups of actuators and
reduce the power pick by about 40%. This allows to increase the total number of thermal actuators by 66%
This is particularly useful when controlling radiant floors where typically there are several loops attached to the
same zone.
Staggered activation of the thermal actuators
Notes 1. Staggered activation with 2 groups of thermal actuators. Group #1 is activated fist and Group # 2 is activated with 2 minutes of
delay to minimize the power pick. It turns out that the power pick is reduced by 40%. This allows the mZone controller to drive up
to 66% more thermal actuators.

Group #2 (N/2 thermal actuators)
2 minutes 2 minutes
Warm-upClosed Partially open
Group #1 (N/2 thermal actuators)
2 minutes
Partially openWarm-up
Start
Fully open
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Model Simultaneous opening
Staggered activation logic with 2 groups
mZone 8
Up to 10 Up to 18
mZone 12
Up to 17 Up to 31
Each digital output (DO) can drive up to 3 thermal actuators
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mZone takes control of hydronic radiant cooling and heating systems

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Below, in a nutshell, are the best 12 reasons to consider mZone for your next radiant cooling project.
1. Messana / Emerson programmable I/O module.
We have based our technology on the new Emerson I/O module custom made and programmed on our
specification.
2. WAGO Terminal Block with CAGE CLAMP® connection technology.
3. Disconnect fuse holder with spare fuse to offer circuit protection. Finger-safe design offers personnel
protection. No fuse pullers or tools required for fuse removal
4. Integrated switching power supply 24Vdc 120W with short circuit, overload and temperature protection.
5. Ethernet adapter to connect to mBox (also used for programing and remote access).
6. Water and dust protected heavy metal enclosure IP65 with powder coating paint.
7. 9/16” (15mm) and 3/4” (19mm) openings for cable pass through with rubber grommets.
8. Additional programmable I/Os with easy accessible plug connectors.
In addition to the most common I/Os pre-wired on the WAGO terminal blocks, there is a set of additional
programmable I/Os that are accessible directly on the Emerson/Messana I/O module.
9. 3/8” cable connector to attach and secure the power cable and provide a strain-relief (supplied separately).
10. Secondary protection fuse to protect the Emerson/Messana I/O module.
11. USB port for service.
12. Adjustable brackets.
3.5” depth allows to enclosure the box in a regular 2x4” wall construction.
12 Reasons to choose mZone
Regardless of the type of conductor, the CAGE CLAMP® has to be opened by pressing it down with a screwdriver. After the
conductor has been inserted into the clamping unit and the spring has been released, the conductor is clamped safely in the
defined contact zone. The predefined clamping force automatically adjusts to the conductor cross section. In contrast to
screw clamp systems, this spring clamp system rules out the possibility that a conductor is inserted into the clamping unit
but not secured.

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8 DO 9 DO 10 DO 11 DO 12 24V
ZONE BUSZONE THERMAL ACTUATORS (24 VDC) AO MIX AI (NTC) AO DI
0V D+ D- SHD 24V 0V Y SUPPLY RETURN AUX AUX
DO 13 DO 14 DO 15 (PWR)
7
5
12
6
7
4
39
1
2
11
10
8
15

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8 DO 9 DO 10 DO 11 DO 12
ZONE BUSZONE THERMAL ACTUATORS (24 VDC)
24V
AO MIX AI (NTC) AO DI
0V D+ D- SHD 24V 0V Y SUPPLY RETURN AUX AUX
DO 13 DO 14 DO 15 (PWR)
DO 1 DO 2 DO 3 DO 4 DO 5 DO 10 DO 11 DO 12
ZONE THERMAL ACTUATORS (24 VDC)
ZONE THERMAL ACTUATORS (24VDC POWERED)
24Vdc powered DOs (Digital Outputs) for two-wire zone valves (24Vdc 5 Amps max).
mZone 8: Can control up to 8 Zones (7 zones if the DO8 is used to control) and up to 10
(18) thermal actuators.
mZone 12: Can control up to 12 zones and drive up to 17 (34) thermal actuators. Up to
three thermal actuators can be connected to one digital output.
Messana thermal actuators come with 1.5mt (5ft) of wire.
To extend use two conductor 18 AWG twisted cable, up to 500 feet (150 m).
DOs can also be programmed to control other 24Vdc devices.
24V
ZONE BUS
0V D+ D- SHD
ZONE BUS
RS485 Master bus (Modbus RTU) for mSense temperature/humidity/IAQ sensors.
0V - 24Vdc provides a stable power supply for the zone sensor bus
D+ (positive) D- (negative) are the RS485 signal lines.
SHL is for the cable shield (do not connect to GND).
AO MIX
24V 0V Y
AO MIX
Analog Output (AO) for 3-way motorized mixing/diverting valve
0V - 24Vdc stable power supply (3W max load)
Y is a 0-10Vdc (or 2-10Vdc) to progressively control the valve (40mA max load)
AI (NTC)
SUPPLY RETURN
AI (NTC) SUPPLY AND RETURN
Analog Input for manifold supply and return temperatures.
Use only NTC thermistors 10k@25ºC Beta 3435.
We recommend using Messana pipe mounted strap-on or well mounted temperature probes.
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I/O’s description

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8 DO 9 DO 10 DO 11 DO 12
ZONE BUSZONE THERMAL ACTUATORS (24 VDC)
24V
AO MIX AI (NTC) AO DI
0V D+ D- SHD 24V 0V Y SUPPLY RETURN AUX AUX
DO 13 DO 14 DO 15 (PWR)
Extract the fuse holder to disconnect the
mZone from the power line or to replace the
fuse. Additional fuse is placed in the pivoting
extraction door. Fuses are safety pulled out
with fingers. No tools are required.
DISCONNECT FUSE HOLDER WITH SPARE FUSE
Fuse holder offer fuse circuit protection and cylindrical fuse model 8.5x31.5 - 2A
(Fuse Size Imperial: 0.33” x 1.24”).
DRY CONTACT RELAY DIGITAL OUTPUT (SOCKET)
Available on mZone12 only.
It requires 24Vdc Finder 44.52.9.024 miniature industrial relays (not included).
AO DI
AUX AUX
AO (AUX) AND DI (AUX)
Auxiliary Analog Output and Digital Input
Analog Output can be used for any 0-10 or 4-20mA device such as fan coils, servo motors, actuators
and proportional zone valves.
Digital Input can be used for door/window or presence sensors, season changeover switch, alarms
and any on/off communication.
Additional programmable AO and DI are available on the Emerson/Messana I/O device.
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LCD Display
LCD Graphic display with membrane keyboard (optional).
It allows to program the device and to read the status of the device. The mechanical contractor can override
outputs, useful for startup and troubleshooting.

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mZone 8 mZone 12
Inputs note 5 Analog Inputs (AI) note 1
Temperature probes, pressure sensors, flow meters, feedback
Resolution 10-bit A/D converter
NTC 10kΩ@25°C Beta 3435 (for supply and return temp) 2 (S/R) 2 (S/R)
Auxiliary programmable AI 1 (AI AUX) 1 (AI AUX)
Additional programmable AI note 5 3 7
Digital Inputs (DI) note 2
Presence or window sensors, season changeover, alarms, On/Off
Additional programmable DI note 5 11 20
Outputs note 5 Digital Outputs (DO) note 3
Thermal actuators, zone valves, pumps, actuators, air units
24Vdc 5Amp powered (for thermal actuators) 8 (DO1-DO8) 12 (DO1-DO12)
Number of thermal actuators (staggered activation) note 6 up to 10 (18) up to 17 (34)
Auxiliary DO dry contact on relay socket note 7 - 2 (DO13-DO14)
Circulator pump (110/220Vac 50-60Hz) on relay socket note 8 1 (DO8) note 9 1 (DO15relay socket)
Analog Outputs (AO) note 4
Mixing valves, servo motors, actuators, fan-coils
Resolution/Accuracy 8 bit converter (2%)
0-10Vdc with 24V power supply for mix-valve 1 (AO MIX 24V/0V/Y) 1 (AO MIX 24V/0V/Y)
Auxiliary programmable AO – 1 (AO AUX)
Additional programmable AO note 5 3 4
Zone Bus RS485 master with shield and 24Vdc power supply up to 8 mSense up to 12 mSense
(Zone Bus 24Vdc/0V/SHL/D+/D -)
Communication With Messana mBox module Ethernet (Modbus TCP)
RS485 slave (Modbus RTU) note 10
Initial setup and programing via Ethernet through a PC
Power Supply 230/110 Vac - 50-60 Hz (15Amps outlet) 85 W 120 W
Technical specifications