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York YMC 2 A Installation Manual
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York YMC 2 A Installation Manual

With optiview control center with r-134a, r-513a, r-1234ze, or r-515b
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YMC
Model A with OptiView Control
2
Center with R-134a, R-513A, R-1234ze, or
R-515B
Installation and Reassembly
Installation Guide
Issue Date: 2024-12-10
Supersedes: 160.78-N1 (1223) and 160.78-N2 (1223)
© 2024 Johnson Controls. All Rights Reserved.
Form Number: 160.78-N1 (1224)

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Summary of Contents for York YMC 2 A

  • Page 1 Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B Installation and Reassembly Installation Guide Form Number: 160.78-N1 (1224) Issue Date: 2024-12-10 Supersedes: 160.78-N1 (1223) and 160.78-N2 (1223) © 2024 Johnson Controls. All Rights Reserved.
  • Page 2 Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B © 2024 Johnson Controls. All Rights Reserved.
  • Page 3 Contents General safety guidelines..........................5 Safety symbols............................5 Wiring warning............................6 Refrigerant warning..........................6 Changeability of this document......................7 Associated literature..........................7 Nomenclature............................8 Overview................................10 Component combinations........................10 Inspection, damage, and shortage....................11 Installation check: request for startup service................11 Chiller data plate..........................12 Removing long-term storage......................12 Shipping and receiving..........................
  • Page 4 Refrigerant relief piping..........................66 Unit piping..............................68 Control wiring.............................68 Power wiring...............................69 Supplied variable speed drive........................69 Refrigerant tubing reassembly......................69 Assembly of straight thread O-ring port fittings..................69 Assembly of O-ring face seal fittings....................... 72 Apply insulation........................... 72 Installation check, request for startup service.................73 Dimensions and weights..........................
  • Page 5 General safety guidelines Important: Read before proceeding. This equipment is a relatively complicated apparatus. During rigging, installation, operation, maintenance, or service, individuals might be exposed to certain components or conditions including, but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and both high and low voltage.
  • Page 6 Wiring warning WARNING External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accordance with the published specifications of Johnson Controls and must be performed only by a qualified electrician.
  • Page 7 Changeability of this document In complying with the Johnson Controls policy for continuous product improvement, the ® information contained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual or product owner.
  • Page 8 Table 2: Associated documentation Manual description Form number 160.78-PW1 Mod A Field Connections Diagram 160.78-PW2 Mod A Field Control, Wiring and MBC Diagrams 160.78-RP1 Mod A Replacement Parts 160.78-RP3 Mod A Replacement Parts Variable Speed Drive 160.78-MR1 Mod A Liquid Chiller Log Sheet Centrifugal Chiller Long Term Storage 50.20-NM5 All Products, Replacement Parts Electrical Connectors...
  • Page 9 Figure 3: Vessel nomenclature example Figure 4: Variable speed drive nomenclature example Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B © 2024 Johnson Controls. All Rights Reserved.
  • Page 10 Overview This manual provides instructions for rigging and installing a YMC Liquid Chilling Unit. Chillers can be shipped as a single factory-assembled, piped, wired package, that requires minimal field labor to make chilled water connections, condenser water connections, refrigerant atmospheric relief connections, and electrical power connections. Refrigerant charges ship separately unless optional condenser isolation valves are ordered.
  • Page 11 Inspection, damage, and shortage Check the unit shipment on arrival to confirm that all major pieces, boxes, and crates are received. When received, check each unit before unloading from the trailer or rail car for any visible signs of damage. Report any damage or signs of possible damage to the transportation company immediately for their inspection.
  • Page 12 Chiller data plate A unit data plate is mounted on the control center assembly of each unit. The data plate provides the following information: • Unit model number • Design working pressure • Water passes • Refrigerant charge • Serial numbers •...
  • Page 13 Figure 6: Tube side components Callout Description Callout Description Tag warning Dennison 8E Flange cover Gauge press 2 diameter 0-30 Gasket Tag GlvSt wire speed Grooved coupling Bush pipe 3/4 - 14 NPTE X Sealing cap Valve, transducer 1/4 NPTE/X Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B ©...
  • Page 14 Shipping and receiving The YMC Mod A chiller can be ordered and shipped in any of the following forms: • Form 1: Shipped complete with refrigerant charge. Form 2: Shipped complete, with refrigerant charge shipped separately. • • Form 3: Shipped in three assemblies. •...
  • Page 15 • Variable speed drive operating coolant, inhibited water Form 3 shipment Before shipping, the unit is completely assembled at the factory. Interconnecting piping is assembled, and the complete unit is wired and leak-tested. Make arrangements with the local service office to ensure refrigerant is on-site when the unit is ready to be charged.
  • Page 16 • The evaporator • The condenser • The variable speed drive • The refrigerant charges shipped separately • The miscellaneous shipped loose items Driveline The driveline compressor and motor assembly is removed from shells and skidded. • All integral wiring is left on the compressor. •...
  • Page 17 Chiller unit The unit is first completely assembled at the factory: • The driveline compressor and motor assembly are mounted, with all necessary interconnecting piping assembled. • The interconnecting piping is assembled and the complete unit is factory leak-tested, then evacuated and shipped charged with a 3 psig to 7 psig (20 kPa to 50 kPa) holding charge of dry nitrogen.
  • Page 18 Form 11 shipment Before shipping, the unit is completely assembled at the factory. The interconnecting piping is assembled and the complete unit is wired and leak-tested. Make arrangements with the local service office to ensure that refrigerant is on-site when the unit is ready to be charged.
  • Page 19 Installation preliminary steps The following information is an overview of the installation process: Determine the location. Foundation requirements Clearance requirements Rig the chiller to the final location. Install the isolators. Locate and place isolator pads, or install optional spring isolators Level the chiller.
  • Page 20 Rigging the unit to the final location To rig the unit to its final location on the floor or mounting pad, complete the following steps: Lift the unit or shell assembly with an overhead lift. If optional shipping skids are used, remove the skids. If the evaporator is to be field insulated, the insulation can be applied to the evaporator while the unit is in the lifted position to gain more access below the shell, if necessary.
  • Page 21 DANGER Do not use a waterbox lifting lug to lift the chiller. CAUTION One chain is required for each lifting point. Use lifting chains with a working load limit each at least 40% of the total shell weight. DANGER Incorrect use of rigging equipment can result in serious injury. Do not operate without correct training and authorization.
  • Page 22 DANGER All weights in this manual are values based on the heaviest known combination at the time of publication. Verify the actual weight for each component to be rigged. This information can be found on the shipping bill of lading or the unit submittal drawings and must be used to verify the weight for all components of the shipment.
  • Page 23 Figure 8: Form 1 and 2 rigging with side spreader bar Callout Description Spreader bar Lifting hole If necessary, to avoid contact with chiller components, install side spreader bars between the evaporator and condenser end sheet lifting chains. See Figure Ensure that the angle of the lifting chains traversing the end sheet is not less than 65°, as shown in Figure...
  • Page 24 Figure 9: Form 1 and 2 rigging without side spreader bar Callout Description Lifting hole With an adequate lifting device, lift the unit slightly off the ground to determine adjustments necessary to keep the unit level. Make adjustments as necessary to level the unit. Unit rigging Form 3 shipment Note: The actual component shipping weights can be found on the shipping bill of lading or the unit submittal drawings.
  • Page 25 CAUTION One lifting chain is required for each lifting point and each chain having a working load limit 40% of condenser and evaporator weight or heat exchanger being lifted. The lifting chains traversing the evaporator and condenser shells should remain 90° ± 10° from horizontal.
  • Page 26 With an adequate lifting device, lift the unit slightly off the ground to determine the adjustments necessary to keep the unit level. Make adjustments as necessary to level the unit. Rigging the compressor motor assembly Table 4: Compressor motor weights Compressor code Weight, lb Weight, kg...
  • Page 27 Make adjustments as necessary. Rigging the variable speed drive Table 5: Variable speed drive weights Model Weight, lb Weight, kg HYP0490XH 1,430 HYP0744XH 2,075 CAUTION The variable speed drive is shipped with glycol in the cooling system. The variable speed drive coolant must be changed to the inhibitor provided with the shipped loose items before starting the unit or a variable speed drive over-temperature fault may occur.
  • Page 28 CAUTION Use lifting chains with working load limit each 35% of total variable speed drive weight. Rigging the MBC panel The MBC panel weighs 50 lb (23 kg). Attach the rigging chains to an adequate lifting device. Attach the chains to the lifting holes at the top of the MBC panel as shown in Figure Figure 13: MBC panel Callout...
  • Page 29 DANGER The OptiView Control Center weighs over 50 lb (23 kg) and a technician and helper are needed for the installation of the panel. Lift the OptiView Control Center and remove all the packing material. Lower the OptiView Control Center on to the supports on the condenser. Attach the OptiView Control Center to the condenser with the correct hardware.
  • Page 30 CAUTION One chain is required for each lifting point. Use lifting chains with working load limit each at least 40% of the total shell weight. The lifting chains traversing the evaporator and condenser shells must remain 90° ±10° from horizontal. A spreader bar can be required to achieve the ±10°. Note: •...
  • Page 31 CAUTION Use lifting chains with working load limit each 70% of total driveline weight. The angle of the lifting chains is critical and damage to the unit can occur if the rigging is not completed as described. With an adequate lifting device, lift the unit slightly off the ground to check for center of gravity.
  • Page 32 CAUTION Use lifting chains with working load limit each 70% of total driveline weight. Make adjustments as necessary. Rigging the variable speed drive Table 7: Variable speed drive weights Model Weight, lb Weight, kg HYP0490XH 1,430 HYP0744XH 2,075 CAUTION The variable speed drive is shipped with glycol in the cooling system. The variable speed drive coolant must be changed to the inhibitor provided with the shipped loose items before starting the unit or a variable speed drive over-temperature fault can occur.
  • Page 33 CAUTION Use lifting chains with working load limit each 35% of total variable speed drive weight. Rigging the MBC panel The MBC panel weighs 50 lb (23 kg). Attach the rigging chains to an adequate lifting device. Attach the chains to the lifting holes at the top of the MBC panel as shown in Figure Figure 18: MBC panel Callout...
  • Page 34 Lower the OptiView Control Center on to the supports on the condenser. Attach the OptiView Control Center to the condenser with the appropriate hardware. Figure 19: OptiView control center Unit rigging Form 9 and Form 10 shipments Note: The actual component shipping weights can be found on the shipping bill of lading or the unit submittal drawings.
  • Page 35 Rigging the unit CAUTION One lifting chain is required for each lifting point and each chain having a working load limit 40% of unit total weight. The lifting chains traversing the evaporator and condenser shells must remain 90° ± 10° from horizontal.
  • Page 36 Figure 21: Form 9 and 10 rigging without side spreader bars Callout Description Lifting hole With an adequate lifting device, lift the unit slightly off the ground to determine adjustments necessary to keep the unit level. Make adjustments as necessary to level the unit. Rigging the variable speed drive Table 8: Variable speed drive weights Model...
  • Page 37 Figure 22: Variable speed drive rigging Callout Description Lifting hole Lift the variable speed drive slightly off the ground to check for center of gravity. Make adjustments as necessary to level the variable speed drive. Lift the variable speed drive and remove all packing material. For variable speed drive weight, Table Lower the variable speed drive on to the supports on the condenser.
  • Page 38 Note: The refrigerant charges are shipped separately. Make arrangements with the local service office to ensure that refrigerant is on-site when unit is ready to be charged. Assembling the condenser Note: The lifting chains along the axis of the condenser shell must not exceed 90° ±10°. A spreader bar can be required to achieve the ±10°.
  • Page 39 If necessary to maintain minimum angles, install side spreader between the condenser end sheets to have the chains as shown in Figure CAUTION The angle of the lifting chains is critical and damage to the unit can occur if the rigging is not completed as described.
  • Page 40 Figure 24: Form 11 evaporator assembly rigging with side spreader bars Callout Description Spreader bar Lifting hole If necessary to maintain minimum angles, install side spreader bars between the evaporator end sheets to have the chains at 90° as shown in Figure CAUTION The angle of the lifting chains is critical and damage to the unit can occur if the rigging is not...
  • Page 41 DANGER The OptiView Control Center weighs over 50 lb (23 kg) and a technician and helper are needed for the installation of the panel. Lift the OptiView Control Center and remove all the packing material. Lower the OptiView Control Center on to the supports on the condenser. Attach the OptiView Control Center to the condenser with the correct hardware.
  • Page 42 Reassembling Form 11 shipments Refer to the following tables for torque values required for reassembly. Table 9: Reassembly torque values Torque value Item Description YORK part number SAP number Quantity ft-lb N•m 4 HCS M24 X 3 X 90MM LG. 021-33185-090 731065 10 HCS M20 X 2.5 X 60MM LG.
  • Page 43 Table 10: Assembly torque metric for metric tube fittings Torque Fitting size Port thread size, mm ft-lb N•m M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M27 x 2 M30 x 2 M33 x 2 M42 x 2 M48 x 2...
  • Page 44 Reassembling Form 3 and Form 7 shipments Refer to the following figures for reassembly hardware identification: piping for Gas Path A: Figure 27 piping for Gas Path B: Figure 28 Form 3 reassembly hardware identification: Figure 29 Form 7 reassembly hardware identification: Figure 30 Figure 31 Drive mounting hardware identification:...
  • Page 45 Install the discharge piece and optional isolation valve between the compressor and the condenser using the correct gaskets and hardware. Install the compressor/motor assembly as follows: a. Lift the compressor/motor assembly according to the Rigging section and remove the packing materials. b.
  • Page 46 Figure 27: YMC piping for Gas Path A Callout Description Rotor Cooling Vapor Return to Evaporator An EEV and isolation valve are available replacement motors. The EEV is not wiried and the valve must be closed for Gas Path A. See G in the following figure for Gas Path B.
  • Page 47 Figure 28: YMC piping for Gas Path B Callout Description Callout Description Rotor cooling vapor return Top of motor To OptiView Compressor flange Electronic expansion valve (EEV) Pipe plug remains installed in all cases Isolation valve plug. See G. Isolation valve open for Gas Path B Bearing cavity liquid drain Isolation valve plug (IV), torque 10 ft-lb...
  • Page 48 Figure 29: YMC Form 3 reassembly hardware identification Callout Description Callout Description Motor Liquid line Vent present only for compressor Optional hot gas Gas Path Revision A Compressor Discharge Check valve Suction Discharge line Condenser Optional discharge isolation valve Evaporator Suction line Table 9 for the torque values.
  • Page 49 Figure 30: YMC Form 7 reassembly hardware identification Callout Description Callout Description Motor Liquid line valve Vent present only for compressor Liquid line Gas Path Revision A Compressor Optional hot gas Check valve Optional hot gas valve Discharge line Suction Optional discharge isolation valve Condenser Discharge...
  • Page 50 Figure 31: Liquid line for Form 7 reassembly Callout Description Callout Description From Condenser Liquid Feed to Motor Cooling Liquid Line Level Control Valve To evaporator Liquid Line Table 9 for the torque values. Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B ©...
  • Page 51 Figure 32: Drive mounting hardware identification Callout Description Callout Description VSD cooling piping, connected at Configuration with sediment union accumulator Configuration without sediment Configuration with sediment accumulator accumulator and valve Table 9 for the torque values. Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B ©...
  • Page 52 Reassembling Form 9 and Form 10 shipments Assemble vibration isolators to the unit, see Install isolators. Level shells in both directions. a. Check the longitudinal alignment of the shell by placing a level on the top of the shell, next to the discharge connection.
  • Page 53 Figure 33: Form 9 and Form 10 reassembly Callout Description Callout Description Magnetic bearing controller OptiView Control Panel Motor Optional discharge isolation valve Compressor Condenser Vent present only for compressor Evaporator Gas Path Revision A Optional hot gas bypass Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B ©...
  • Page 54 Reassembling Form 11 shipments Bolt the tube sheets together as shown in the following figure. Note: The outside surfaces of the tube sheets must be flush. The internal surfaces of the mating flanges have match marks on them that are placed there during factory assembly.
  • Page 55 Reconnect motor power leads in the variable speed drive to the T1, T2, and T3 terminals and torque in accordance with the labels in the drive. Reconnect all unit wiring and harnesses. Refer to YMC Unit Wiring and Field Control Modifications (Form 160.78-PW2).
  • Page 56 Callout Description Callout Description Check valve Evaporator Variable speed drive Optional hot gas valve Magnetic bearing controller Condenser Motor Optional hot gas Compressor Figure 36: Liquid line for Form 11 reassembly Callout Description Callout Description From Condenser Liquid Feed to Motor Cooling Liquid Line Level Control Valve To evaporator Liquid Line...
  • Page 57 Installation final steps Install isolators Neoprene isolator pads are provided as standard and typically satisfy the installation engineer's vibration isolation requirements when the chiller foundation is not likely to transmit to occupied spaces. Optional spring isolators can be selected when the location of the equipment room floor dictates more stringent limits on vibration input.
  • Page 58 Neoprene isolator pad dimensions Figure 37: Neoprene isolators, unit weight ≤ 16,365 lb (7,423 kg), in. (mm) Callout Description Shell End sheet See the isolator height figure Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B © 2024 Johnson Controls. All Rights Reserved.
  • Page 59 Figure 38: Neoprene isolators, unit weight 16,366 lb to 28,896 lb (7,424 kg to 13,107 kg), in. (mm) Callout Description Shell End sheet See the isolator height figure Figure 39: Isolator height, in. (mm) Callout Description Mounting bracket Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B ©...
  • Page 60 Figure 40: Skid options Table 12: Shell length and dimensions Shell length, ft Dimension A, in. (mm) Dimension B, in. Dimension C, in. Dimension D, in. Dimension E, in. (mm) (mm) (mm) (mm) 8 (2.4) 66 (1,676) 32 (8,13) 34 (864) 10 (254) 8 (203) 10 (3.0)
  • Page 61 Leveling the unit Check the longitudinal alignment of the unit by placing a level on the top center of the evaporator shell under the compressor and motor assembly. Check the transverse alignment by placing a level on top of the shell end sheets. Rotate the leveling bolts one turn at a time, in sequence, until both of the following occur: The unit end sheets are clear of the floor by the dimension shown in the corresponding figure in...
  • Page 62 Figure 42: Four spring isolators, unit weight 19,563 lb to 24,456 lb (8,874 kg to 11,093 kg), in. (mm) Callout Description Callout Description Shell Cap screw End sheet Adjusting bolt Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B ©...
  • Page 63 Figure 43: Skid options Table 13: Dimensions Operating unit weight, Dimension, in. (mm) lb (kg) Up to 35,000 (15,880) 62 (1,575) 31 (787) 31 (787) 6 (152) 6 7/8 (175) 5 1/2 (140) Making connections After the unit is leveled, place wedges and shims under each corner to solidly support the unit. Connect and hang the piping, adjust the connections, and check for correct alignment.
  • Page 64 Piping connections After the unit is leveled and wedged in place for optional spring isolators, the piping connections for chilled water, condenser water and refrigerant relief can be made. Arrange the piping with offsets for flexibility. Support and brace the piping independently of the unit to avoid strain on the unit and vibration transmission.
  • Page 65 Figure 44: Schematic of a typical piping arrangement Callout Description Callout Description Condenser Chiller Evaporator Cooling load Compressor Strainer Motor Chiller water pump Cooling tower Cooling tower pump Controlled cooling tower bypass valve, if necessary Chilled water Foreign objects that could lodge in, or block flow through, the evaporator and condenser tubes must be kept out of the water circuit.
  • Page 66 Condenser water circuit For correct operation of the unit, the condenser refrigerant pressure must be maintained above the evaporator pressure. If operating conditions are to fulfill this requirement, do not attempt to control the condenser water temperature by means of automatic valves, cycling of the cooling tower fan, or other means.
  • Page 67 Figure 45: Typical refrigerant vent piping Callout Description Horizontal misaligned Vertical offset Compressed Note: When installing relief piping, there must not be any piping strain. Relief piping must be • correctly aligned and supported to eliminate any possible piping strain. •...
  • Page 68 Figure 46: Typical refrigerant vent piping, continued Callout Description Callout Description Vent to atmosphere Condenser Support the vent piping to avoid strain Dual relief valves on the relief valve and piping Flexible connector Condensation trap Relief valves, see note Flanged joint for disassembly Evaporator Note: Shells can be provided with one or two relief valves, depending on the shell size.
  • Page 69 Power wiring CAUTION Do not cut wires to final length or make final connections to starter power input terminals until approved by the Johnson Controls representative. Supplied variable speed drive The factory-mounted variable speed drive does not require wiring to the compressor motor. The motor power wiring is factory connected to the variable speed drive.
  • Page 70 Assembling adjustable end fittings Inspect to ensure that both matching parts are free of burrs, nicks, scratches or any foreign particles. Install the O-ring on port end of fitting, if it is not pre-installed. Take care not to nick the O- ring.
  • Page 71 To align the tube end of the fitting to accept the incoming tube or hose assembly, unscrew by the required amount, but not more than one full turn. More than one turn makes the locknut push the O-ring into the machine threads beyond the fitting land area during Step 8. Using two wrenches, hold fitting in the appropriate position and tighten locknut to the appropriate torque value shown in Table 10...
  • Page 72 Figure 51: SAE or ISO 6149 straight thread O-ring port Callout Description Sealed with O-ring Threaded for holding power Assembly of O-ring face seal fittings The male end and female nut of face seal fittings have UN/UNF straight threads. An elastomeric O- ring is fitted into the grooved male end.
  • Page 73 Units are provided factory anti-sweat insulated on order at additional cost. This includes all low temperature surfaces except the two cooler liquid heads. Figure 52: FAB unit insulation Note: Bold lines and shaded components represent insulation. Callout Description Callout Description Condenser Liquid line Evaporator...
  • Page 74 price, can be scheduled. Notify the Johnson Controls office using the Installation Checklist and Request Form (Form 160.78-CL1). Model A with OptiView Control Center with R-134a, R-513A, R-1234ze, or R-515B © 2024 Johnson Controls. All Rights Reserved.
  • Page 75 Dimensions and weights Unit dimensions Table 14: Additional operating height clearance to floor, in. (mm) Type of chiller mounting Neoprene pad isolators 1 3/4 in. (45 mm) Spring isolators 1 in. deflection 1 in. (25 mm) Direct mount 3/4 in. (19 mm) Figure 53: Dimensions for 197 and 246 compressor units, ft-in (mm) Callout Description...
  • Page 76 Table 15: Dimensions for FAB-197 and FAB-205 compressor units, ft in. (mm) Evaporator Condenser Dimensions for 197 and 205 compressor units, ft - in (mm) code code EA2510 CA2110 5ft 5 in. 7ft 4 in. 1ft 3 1/2 in. 1ft 3 1/2 in. 10ft (1651) (2235)
  • Page 77 Weights Important: These tables are for reference only. Refer to product submittal drawings for detailed weight information specific to the unit ordered. Table 16: Approximate unit weights at max tube count using 150 psi compact waterboxes Compressor Evaporator Condenser Shipping Operating Est.
  • Page 78 0.5556. Example: 10.0°F range x 0.5556 = 5.6 °C range   © 2024 Johnson Controls. 5000 Renaissance Drive, New Freedom, York, PA 17349, USA. Subject to change without notice. All rights reserved. © 2024 Johnson Controls. All Rights Reserved.