final testing report tes

T.E.S.-001 Test Procedure and Results

THERMAL EXTRACTION SYSTEM

Utah State University

Senior Design Test Team

Colton Remund, Zachery Pope, Logan Gumucio, Craig Hastings

Spring 2015

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Table Of Contents

Purpose 4

Goals From Testing 4

1. Building the Control Volume (CV) 4

1.1 Items Required 5

2. Controlling The Environment 5

2.1 Temperature 5

2.2 Humidity 5

2.3 Measuring Temperature and Humidity within the Environment

5

3. Building the Test On Body Interface (TOBI)

5

3.1 Items Required 5-6

3.2 Preparing the Test On Body Interface (TOBI)

6

4. Performing Each Test 6-9

4.1 Safety 6

4.2 Surface Temperature Sensors

6-7

4.3 Temperature Sensor Locations

7

4.4 Setup 7-8

4.5 Test Parameters 8

4.6 Running Each Test 8-9

a) TOBI Dry-No Vest, No Power 8

b) Dead Test-Vest On, No Power 8-9

c) Total Power-Vest On, Power On 9

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5. Calculations 9-12

5.1 Measuring Total Heat Transfer 9-10

5.2 Measuring Heat Transfer Due to Evaporation

10

5.3 Calculations for Model 11-12

6. Test Report 13-19

6.1 Descriptions of tests conducted 13-14

6.2 Results of Tests 14-17

6.3 Discussion on Results 17

6.4 Recommendations for Future Work 17-18

6.5 Conclusion of Testing Results 18

Appendix A: Matlab Code 19

Appendix B: Spec. Sheets and Product Specifications 20

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Purpose

The purpose of this procedure is to test the effectiveness of heat removal from the vest system, TES-001, designed by Thermal Extraction Systems. To do this, testing will be done in various controlled environments to establish an expected performance. The main variables being controlled within the testing environment will be the humidity and temperature conditions. These in turn will highlight real world conditions that military personnel would operate in while utilizing TES technology.

Description of System The TES-001 is designed to remove excess heat away from the body of select Air Force Battlefield Airmen for the duration of entire missions while they are performing their duties. In hot environments, soldiers are at risk of heat stress and heat stroke. The TES-001 needs to be able to maintain a soldiers normal core body temperature in order to reduce the risk of soldiers being adversely affected by overheating.

The TES-001 provides cooling through the means of evaporative and convective cooling. Airflow is created using two axial fans in series that are mounted on the backpack of the soldier. The airflow passes through a manifold that splits the airflow in two and routes it through two flexible tubes that connect the fans to the designed vest. The vest is designed to be worn underneath the soldier’s armor and on top of a compression shirt. The vest utilizes a layout of channels created by foam inserts. The air passes through these channels and over the compression shirt. This enhances evaporation of the soldier’s perspiration and subsequently creates a cooling effect.

The AFRL has stated that the objective weight is less than 2 pounds. The threshold is 4 pounds but could be heavier if the design works well enough to justify it. The TES-001 weighs in at 5 lbs. While keeping the system light, it is also rugged. It has the ability to handle rough usage. During a mission, the system can handle bumping into other objects and being oriented in different directions since the soldier could be moving in a variety of ways.

Goals From Testing 1. Measure the heat removed by TES-001

a. Compare to previous calculations from fall semester testing b. Understand what changes may need to be made to increase performance

2. Measure the moisture evaporated by TES-001 a. Compare with previous calculations from fall semester testing

3. Ensure flow in all channels 4. Ensure comfort and mobility

1. Building the Control Volume (CV) The environment will be controlled by building a 4’x 4’ x 4’ insulated control volume (CV). The CV may be accessed on the top as well as one of the sides. The CV will be built using foam board insulation (4’ x 4’ x 4’) with a wood frame. The wooden frame will be built to house the insulation and serve as support and ease of moving if needed. Edges along the bottom and corner walls will be sealed using tape and glue to hold in humidity, temperature, as well as solidifying the structure. The top of the CV will be sealed by a plastic sheet, as well as covered with a layer of insulating foam board. One of the side foam boards will provide access to the inside of the CV, as it can be removed from the wooden frame for ease of access and moving parts.

Space heaters and humidifiers will be placed within the CV to provide the needed temperature and humidity levels, with power chords fed through a sealed hole in the CV wall. These heaters and humidifiers will sit on hardboard on the floor of the CV for added stability and protection. A 120mm fan will be mounted on the back wall above the heaters and humidifiers to create circulation. A small foam board will also be placed between the heating/humidifying element and the Test On Body Interface (TOBI), in order to isolate TOBI from direct radiative contact. This spacer will hold a wireless sensor which measures the ambient temperature and humidity within the CV and transmits it to an outside display. Throughout each test, the temperature will be measured and logged every second.

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1.1 Items Required Foam Board Insulation ( 6 – 4’x4’ sizes) 2” x 4” (12-4’ lengths) Screws (AR) Humidifiers (2) Wireless Temp/Humidity sensor Radiative Space Heaters (2) Heater tape (AR) Gorilla Glue 5 mil thick plastic sheet (4’ x 4’) 120mm fan Wire Hanger Insulating Foam board spacer(36” x 24”) with leg risers(3-4” x 2”) Hard Board (2-2’ x 4’) Inline vent draft blocker (4” diameter)

2. Controlling The Environment

2.1 Temperature Temperature will be provided by space heaters within the CV, while additional heat will be added to the CV from the humidifiers and prototype. The top insulating foam board will be removed if temperature exceeds set parameters (+ 5°F of set point). This will be done by sliding/lifting the insulating foam board off of the plastic sheet, allowing more heat to leave the CV and maintain the target environment while maintaining humidity. The uncovered surface area of the sheet will be determined by the level of temperature offset within the CV.

2.2 Humidity Humidity shall be controlled by powering two humidifiers to reach a steady target level and then powering them off. As it leaves the target level, the humidifiers will be re-activated to restore steady target levels. If the humidity becomes too high the vent from the inline blocker, located on the lower rear wall of the CV, will be opened to allow moisture to escape as required.

.

2.3 Measuring Temperature and Humidity within the Environment Humidity and temperature within the environment will be measured using a Meade TM005-X Wireless Thermo-Hygrometer. The wireless sensor will be mounted on the separation barrier inside the testing environment, and will transmit readings to the outside receiver. By doing this, the temperature and humidity inside the environment can be adjusted to the desired conditions.

3. Building the Test On Body Interface (TOBI)

To ensure that the TES-001 can remove heat, a test dummy was created, known as the Test On Body Interface (TOBI). Because the TES-001 is dependent on evaporative cooling, TOBI will need to have a form of ‘sweating’. By using an immersion heater within the water filled dummy, in conjunction with thermistors, the rate at which the TES-001 can remove heat may be determined.

3.1 Items Required Mannequin Torso Immersion Heater

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Acrylic Thermistors CAT 5 Cable Polyethylene tubing(3/8’’ x 1/4’’) Wicking/Compression Shirt Drum for “sweat” storage Fish Tank Pump Barbed Ball Flow Valve Water (as required) Medical Tape

3.2 Preparing the Test On Body Interface (TOBI) TOBI will be prepared by filling the mannequin torso with water. An immersion heater will then be attached to an acrylic board and placed into the water. This will provide needed separation between the immersion heater and mannequin as it is heated. Small tubing will be oriented around the outside of TOBI’s surface, and secured into place with a wicking/compression shirt, to also simulate sweating through clothing. The tubing will run from a drum full of water outside the CV to the mannequin. The tubing will cover regions where the majority of ‘sweating’ is to occur and will have small holes where water may drip out. The flow of water through these holes will be managed by placing a flow valve at the end of the tubing. This will allow an increase/decrease in pressure and manage the water flow through the holes.

Figure 1. Visual representation of testing setup within Control Volume (CV). The mannequin torso (TOBI) will be placed within the chamber where heaters and humidifiers will control the temperature and humidity. The TOBI sweating mechanism allows the inner layers of the compression shirt to remain moist, thus allowing continuous testing of the system.

4. Performing Each Test All thermal tests were performed in a controlled environment, using a 64 ft3 testing chamber. The testing

environment was insulated on all sides and sealed to keep the moisture inside the environment. The heat was

controlled using two space heaters, and the humidity was controlled using two humidifiers. A hollow mannequin

(TOBI) was filled with water and heated to a temperature of 102°F. Sweating was simulated by utilizing a pump and

drip line that wrapped around TOBI’s body. The flow rate through the pinholes of the drip line were controlled to

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match the amount of sweat produced by an individual in that area of the body. A compression shirt was then placed

over TOBI, and the vest was placed over the compression shirt. Power was supplied to the fan using a variable power

supply set at the voltage of the chosen battery for the system. Temperature data was measured using eight

independent thermocouples, connected to a NI Mytemp/MyDaq system, which then was plotted using a Labview

program.

4.1 Safety Ensure all pumps, heaters, and electrical equipment are properly grounded Ensure that all heaters and components do not exceed recommended temperatures Any water spills or leaks must be cleaned immediately to ensure safe work environment Ensure that space heater will not melt or cause damage to the CV or TOBI in any way while running

4.2 Surface Temperature Sensors Thermistors will be used to monitor the internal and outer surface temperatures of various locations on TOBI. The thermistors that will be used are Amphenol NTC Type MS Epoxy Coated thermistors. The thermistors will input data into a NI MyTemp unit which is connected to a NI MyDaq. This signal will then be processed by a Labview virtual instrument. Using the virtual instrument allows the surface temperature of various locations to be continuously monitored and recorded.

4.3 Temperature Sensor Locations A wireless temperature/humidity sensor will be located within the CV to measure conditions of the ambient temperature ( ). Thermistors will be located within the water on the inside of TOBI, as well as various locations on T inf

TOBI’s surface area. The locations of the various thermistors are shown below in Figure 2.

Figure 2: Thermistor locations on the outside surface of TOBI. Back view left; one sensor each located on upper and lower back. Front view right; two sensors located on chest, two sensors located under the armpits, and one sensor located on lower abdomen.

4.4 Setup Boot up computer Labview program Initialize calibration of Thermistors Test wireless Temperature/Humidity sensor and Thermistors to ensure proper function. Fill the tank of water for “sweat” supply throughout testing.

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4.5 Test Parameters The test parameters are given so that tests may be repeatable and informative.

110°F, 20% Humidity 90°F, 90% Humidity TOBI will be heated to Heat Stress levels (approx. 102°F)

4.6 Running Each Test For each of the test parameters mentioned above in section 4.5, three experiments were tested. These different tests were known as

TOBI - No vest, No power Dead TES- Vest On, No power TES- Vest On, Power On

Detailed steps for each of these tests are as follows:

a) TOBI - No vest, No power

1. Check TOBI: make sure sensors and hydration line are securely in place. 2. Check the Labview temperature VI and verify all temperature sensors are responding. 3. Seal up the box. 4. Engage the CV fan, heaters, and humidifiers. 5. Monitor wireless sensor and thermistors for consistency in temperature readings. 6. As readings begin to reach target test parameters and steady state, turn off heaters and humidifiers. 7. Once steady, run Labview software, collecting data every second, for 20 minutes, and engage hydration line

as needed. a. If temperature begins to rise too far above target level, remove roof to bleed heat off until target

level is re-established. Then replace the roof on the CV. Threshold is 5 degrees.±

b. If temperature begins to descend too far below target level, reactivate heater until target level is reached. Then deactivate heater. Threshold is 5 degrees.±

c. If humidity begins to rise too far above target level, open the inline vent draft blocker and expose predefined plastic sheet flap on the roof above the vent until target level is reached. Then re-seal the roof flap and insulation board.

d. If humidity begins to descend too far below target level, reactivate humidifier until target level is reached. Then deactivate humidifier.

e. For ”sweating” cases, make sure the flow rate of the hydration line isn’t exceeding roughly 1 L/hr. Adjust the flow valve as needed.

8. Upon completion, take saved data file and import into Matlab in order to plot and calculate heat transfer. 9. Note differences between thermistors and record any potential differences. 10. Analyze results and compare with original values.

b) Dead TES - Vest on, No power

1. Check TOBI: make sure sensors and hydration line are securely in place. 2. Check the Labview temperature VI and verify all temperature sensors are responding. 3. Put TES-001 on TOBI. 4. Make sure power on the vest is off. 5. Seal up the box. 6. Engage the CV fan, heaters, and humidifiers. 7. Monitor wireless sensor and thermistors for consistency in temperature and humidity readings. 8. As readings begin to reach target test parameter and steady state, turn off heaters and humidifiers. 9. Once steady, double check that TES-001 is off, and has no power. Engage hydration line as needed. 10. Run Labview software, collecting data every second, for 20 minutes.

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a. If temperature begins to rise too far above target level, remove roof to bleed heat off until target level is re-established. Then replace the roof on the CV. Threshold is 5 degrees.±






c) TES - Vest on, Power on

1. Check TOBI: make sure sensors and hydration line are securely in place. 2. Check the Labview temperature VI and verify all temperature sensors are responding. 3. Put TES-001 on TOBI. 4. Make sure connections to power the vest are connected properly and secure. 5. Seal up the box. 6. Engage the CV fan, heaters, and humidifiers. 7. Monitor wireless sensor and thermistors for consistency in temperature and humidity readings. 8. As readings begin to reach target test parameter and steady state, turn off heaters and humidifiers. 9. Once steady, engage TES-001 and hydration line. 10. Run Labview software, collecting data every second, for 20 minutes.

a. If temperature begins to rise too far above target level, remove roof to bleed heat off until target level is re-established. Then replace the roof on the CV. Threshold is 5 degrees.±






5. Calculations 5.1 Measuring Total Heat Transfer The goal of testing the effectiveness of the TES-001 is to see how large of a temperature difference from TOBI’s starting and ending points can be obtained within the given environment parameters. Testing shall be done by first reaching the desired humidity and temperature within the CV and TOBI. The TES-001 will then be turned on and the temperature difference within TOBI will be measured. Temperature measurements will be taken every second for a period of 20 minutes. The heat removed will be calculated using the equation derived from the resistance network shown in Figure 3 below.

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Figure 3: The resistance network for the Testing apparatus. Starting at left with the internal water temperature within TOBI, and moving to the right through the thermal resistance of TOBI’s thickness, TES-001 vest with convection and conduction resistances, and then into the environmental chamber.

EQ.1

Where

= Total heat being removedQTotal

Tw = Temperature of the water inside TOBI cp = Specific heat of water m = Mass of water in TOBI RT = Thermal resistance of TOBI This equation can be used to determine the heat removed at each sensor location, as well as the absolute heat removal for the entire system.

5.2 Measuring Heat Transfer Due to Evaporation The heat transfer from evaporation will be measured by analyzing the change in weight of a wetted t-shirt. The system will run with a pre-weighed wetted t-shirt. This shirt will be placed over TOBI and the TES-001 will be placed over the shirt and be turned on. The test will run for a period of 20 minutes. The final weight of the t-shirt will be weighed. With the following equation, the heat transfer due to an overall change in moisture will be calculated:

weight/ΔtimeQevap = Hvap *Δ EQ.2

Where = Heat transfer of the system,Qevap

= Latent heat of vaporization,Hvap

= Change in weight over time of 20 minutes.weight/ΔtimeΔ

The overall heat transfer due to convection will be calculated and compared with fall testing results.

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5.3 Calculations for Model

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6 Test Report

6.1 Description of Tests Conducted

The following tests were performed according to the procedures discussed in Section 4 of this report

1. Dry Testing (113°F, 20% humidity) The internal temperature of TOBI was 102°F at the beginning of the tests. The goal of this test was to get

results of heat transfer from TOBI to the environment without the aid of evaporation. The heat transfer was determined by observing the change of TOBI’s internal temperature over a given period of time over 20 minutes.

The drip line was turned off and the compression shirt kept dry.

2. Dry Testing with vest and fan on/fan off (115-118°F, 20-25% humidity) The purpose of this test was to determine the heat transfer of TOBI while the drip line was off and the vest

was on. The heat transfer was determined by observing the change of TOBI’s internal temperature over a given period of time of 20 minutes.

Two tests were ran: one with the fan on, and one with the fan off.

3. Wet testing (Dual axial fan, Blower fan 2.8 A Large, 3.8 A Large, 3.8 A compact, 115-118°F, 20% humidity)

The wet testing was the standard test used for determining the heat transfer produced by the vest. These tests were ran with the drip line running, the vest on, and the fan running. The heat transfer was determined by observing the change of TOBI’s internal temperature over a given period of time of 20 minutes. This multiplied by the specific heat and mass of the water inside of TOBI gave the amount of heat transferred from TOBI.

Two/Three tests were ran to check repeatability of results. The best performer of the above test moved on to additional testing at higher humidities and lower

temperature

4. Wet testing (Dual axial fan, 95°F, 50% humidity) Similar wet testing procedure performed as #3, except at 95°F and 50% humidity Two/Three tests were ran to check repeatability of results

6. Wet testing (Dual axial fan, 95°F, 65% humidity) Similar testing procedure performed as #3, except at 95°F and 65% humidity Two/Three tests were ran to check repeatability of results

6. Wet testing (Dual axial fan, 95°F, 80% humidity) Similar testing procedure performed as #3, except at 95°F and 80% humidity Two/Three tests were ran to check repeatability of results

7. Mobility Tests (Qualitative) Qualitative testing

Run Test Vest was worn while the subject was running, areas of the body that were being cooled by

the vest were noted, range of motion and comfort were also noted Unobstructed range of motion while running, and noticeable cooling were considered

passing Rollover Test

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The vest was worn while the subject attempted to roll over. Comfort and range were noted

Ability to roll over without damage to the fan assembly and/or disconnection of components was considered passing

Side Lay Test The vest was worn while the subject laid on both side to check for comfort, any range of

motion limitations and closing of air channels/tubing was noted Discomfort is bearable is considered passing

Range of Motion testing The vest was worn while various physical motions were performed by the subject. Any

limitations and comfort issues were noted Full range of motion is considered passing

8. Destruction Tests Qualitative testing

Drop test Drop Fan assembly from a five foot drop level. Repeat until 1 or both fans stop working or

visible damage to fan manifold If Sample survives 10 drops without physical damage, and fans still operational is

considered passing Water Spray Test

Mist fan assembly with water bottle until fan stops working or 4 hours have passed Sand Tests

Funnel sand particles through fan assembly until fan assembly stops working or 4 hours have passed

6.2 Results from Testing

Decision Matrix Summary

Table 1. Summary of fan decision matrix from testing

Importance Property Measured Blower: 2.8 A Single Axial Double Axial

Primary Heat Removed at 118°F 20-30% RH 160-170 60-70 120-140

Primary Maximum Flow Rate (CFM) 55 68 68

Primary Current Draw (Amps) 2.4 0.7 1.4

Secondary Weight (oz) 9.8 6.0 12.0

Secondary Fan Dimensions (mm) 120 x 120 x 32 80 x 80 x 38 80 x 80 x 76

Secondary Static Pressure Drop (in. H2O) 3.5 0.6 1.2

Secondary Total run time (hours) 2.6 9.1 4.5

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TOBI With Vest and No Power To Fan Dry

Table 2. Testing data for full suit up and dry

118°F and 20% 90°F and 50% 90°F and 80%

Change Water Temperature (°F)

-0.1 0.2 0.3

Watts Cooled -4 7.9 8.9

Btu/hr Cooled -16 27 30

Table 3. Testing data for Dual Axial Fan Set-Up at 118°F and 20-25% humidity wet

118°F and 20% 90°F and 50% 90°F and 80%

Change Water Temperature (°F)

0.1 1.0 1.2

Watts Cooled -14 34 29

Btu/hr Cooled -48 119 99

Blower Fan 2.8 Amp Large

Table 4. Testing data for 2.8 Amp blower Set-Up at 118°F and 20-25% humidity

Trial 1 Trial 2 Trial 3 Average

Change Water Temperature (°F) 5.6 4.9 3.5 4.7

Watts Cooled 190 167 116 160

Btu/hr Cooled 648 157 398 546

Blower Fan 3.8 Amp Large

Table 5. Testing data for 3.8 Amp Large blower Set-Up at 118°F and 20-25% humidity

Trial 1 Trail 2 Trial 3 Average

Change Water Temperature (°F) 3.7 3.9 Na 3.8

Watts Cooled 127 132 Na 129

Btu/hr Cooled 433 450 Na 442

Blower Fan 3.8 Amp Compact

Table 6. Testing data for 3.8 Amp Compact blower at 118°F and 20-25% humidity


Change Water Temperature (°F) 2.4 2.6 NA 2.5

Watts Cooled 81 89 NA 85

Btu/hr Cooled 304 279 NA 290

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Single Axial

Table 7. Testing data for Single Axial Fan Set-Up at 118°F and 20-25% humidity


Change Water Temperature (°F) 2.3 1.9 1.9 2

Watts Cooled 77.9 66.2 63 69

Btu/hr Cooled 266.1 226 215 236

Dual Axial

Table 8. Testing data for Dual Axial Fan Set-Up at 118°F and 20-25% humidity


Change Water Temperature (°F) 3.6 4.1 3.6 3.8

Watts Cooled 122 138 122 127

Btu/hr Cooled 419 471 417 435

Table 9. Testing data for Dual Axial Fan Set-Up 95°F and 50% humidity

Trial 1 Trail 2 Trial 3 Average Net Cooling

Change Water Temperature (°F) 4.1 4.1 Na 4.1 3.2

Watts Cooled 139 137 Na 138 108

Btu/hr Cooled 470 477 Na 471 368



Change Water Temperature (°F) 3.0 3.4 3.0 3.1 2.3

Watts Cooled 102 113 100 105 78

Btu/hr Cooled 351 385 341 357 266



Change Water Temperature (°F) 2.1 1.7 Na 1.9 1.1

Watts Cooled 69 59 Na 64 35

Btu/hr Cooled 234 201 Na 218 120

Table 12. Mobility Tests of dual axial results (Qualitative)

Type of test Results Range of Movement of Arms and

Legs Full range of Motion Possible (PASS)

Side Lay test Feels similar to laying on a Mag Pouch, but Flow obstructed on that side(PASS)

Run Test Unobstructed range of Motion. Maintained Cooling (PASS)

Rollover Test Equipment survived rollover test (PASS)

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Table 13. Destruction Tests

Type of test Results Sand Fill Fan Test Not Completed

Water Spray Fan Test Not Completed

Repeating Drop Fan Test 15 Drops before visible damage on fan. Both fans still operational (PASS)

6.3 Discussion on Test Results

The amount of cooling produced by the vest was able to achieve the optimum goal of 200 BTU/hr (58.6 Watts) that was set by the TES group. The vest was able to achieve 138 Watts of cooling with a dual axial fan configuration at 95°F and 50% relative humidity. At 118°F and 20-25% relative humidity, the dual axial fan produced 127 Watts of cooling and the 2.8 amp blower fan produced 160 Watts of cooling.

Humidity plays an important role in this vest design and as expected, the cooling rates drop as the relative humidity is increased. Increasing the relative humidity from 25% to 50% decreased the cooling rate of the vest by 15% for the dual axial configuration. In addition, increasing the relative humidity from 25% to 65% produced a 17% decrease in cooling rate for the dual axial configuration.

With the dual axial fan set up, a run time of 100 minutes longer can be achieved over the blower. The blower fan produced more cooling, but at the cost of run time. The ratio of Watts out to Watts in achieved for the two system configurations was 6.0 for the dual axial fan, and 4.8 for the blower fan. Based on these numbers the dual axial fan configuration was chosen for our system.

The results of the mobility tests were that the vest did not impede motion for nearly all of the physical motions tested. The vest passed the running and walking motion tests. The vest also passed the side lay test because it was determined that is was no less comfortable or impeding than rolling onto a mag pouch. The airflow in that portion of the vest was restricted, but air continued to flow through the other side of the vest. The vest failed the rollover test based on the fact that a subject could not rollover with the vest on without damaging the vest components. The vest passed all other arm and leg motion that was performed during testing.

6.4 Recommendations for Future Work

Shrink Wrap Wiring: It was decided that it would be best to shrink wrap the wire on just two parts of the tubing: one over the wiring between the switch and the fuse, the other between the fuse and the module connection. This will allow access to all the necessary parts, protect the main portion of wiring, and make the build look a lot cleaner. A smoother, cleaner, and more efficient way to protect the wiring would need to be found if this system were to be implemented in the field.

New Fan and Battery Module: The biggest change that is required is further revision to the Fan and Battery Module. Mainly the MOLLE attachment points and battery housing location. A large amount of time was put into getting the module to connect with the ballistic vest securely. Once it was on, we really got a good view of the now extended soldier profile due to the added battery housing. This was especially noticeable when laying prone, and completely prevented the possibility of rolling over and sitting up against a surface comfortably.

Required Modifications: In order to condense the module into a more compact/mobile friendly device, the battery housing needs to be moved to the "roof"or top of the module. This would allow the battery to run horizontally over the top, extending just over a small portion of the tube barbs. In doing so, some modifications need to be done in order to properly house the battery in this new location, as well as to provide a more secure connection to the Soldiers Gear.

A simple L-shaped housing will allow the Battery to maintain a snug fit, and be held in place with velcro straps that run through slots built into the housing. The back of the L-shape will be up against the soldiers body. The module now will just need to have the

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empty space created by the angle on that side filled in.This will provide a secure base for the housing. The angle on the opposite side will stay.

On the back side of the L-shape housing, near its base, it will provide 1 of the 3 MOLLE attachment points, being located just over the barbs.

The barbs might need to be moved slightly closer to the soldiers body and down (see sketch) and will need to be located such that the Tubing has enough clearance between it and the now slightly extended battery housing above it.

The 2nd MOLLE attachment point will need to be moved from off the old angled side and placed where the vertical slots are now. The vertical slots are being entirely removed from the design.

The 3rd MOLLE attachment point will be a separate piece entirely and will attach to the module where the two fans are screwed together. It will bolt down on that same connection, and span the back side where the fans are held together.

These changes/modifications will result in keeping the module closer to the Soldiers body, eliminating an extended profile, and provide greater mobility for the soldier.

Dehumidifier: Since TES-001’s effectiveness is humidity dependant, a future design would be to implement a dehumidifying booster to the fan system. This booster would allow the air to pass through, while dehumidifying the air. This would allow for more sweat to be pulled off of the soldier and extract more heat from them.

6.5 Conclusion of Testing Results

The testing results allowed the team to verify the TES-001 design. From testing with the highest cooling potential of 120 Watts, it is expected the design will be able to cool the soldier effectively in hot and dry climates. It is also expected that the TES-001 design to be able to cool the soldier in mid-level humidities. With mobility testing the system is considered a feasible design for the solder and not be obstructed from his/her duties. From the completed destruction testing, the system is expected to be able to survive the abusive environment of the soldier and still perform as designed.

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Appendix A: Matlab Code

QCode to find total immersion cooling of system.

clc; close all; clear all; %% code to import data from labview save file and save as a heat transfer % import data from tab delimited text file T=dlmread('118 20% overheat blower 2.8 amp'); seconds=length(T(:,1)); % calculate average surface temperature at each second summ=0; for i=1:seconds Tavg(i)=mean(T(i,2:6));

s(i)=i; end % Plot Temperature Data figure(1) plot(s, T(:,1), 'm') hold on plot(s, T(:,2), 'k') plot(s, T(:,3), 'g') plot(s, T(:,4), '--') plot(s, T(:,5),'r') plot(s, T(:,6),'c') plot(s, T(:,7),':') plot(s, Tavg,'-.') xlabel('Time (seconds)') ylabel('Temperature (fahrenheit)') title('Temperature Profile') legend('T1','T2','T3','T4','T5', 'T6','T7') %properties of water mass_water=37.9 %10 gallons of water in kilograms cp_water=4.186 %J/kg*k %% Calculate overall heat transfer by immersion cooling Immersion_Cool=mass_water*cp_water*(max(T(:,1))-min(T(:,1)))/seconds*1000*5/9

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Appendix B: Product Specifications and Spec. Sheets

Meade TM005X-M wireless sensor: (Product Sheet and call to company. Sheet not downloadable) Temperature Range and Resolution: -4 - 158 , ± 1 Humidity Range: 5 - 99%, ± 3%

Water Pump: Flow rate accuracy: ± 3%

TEK Power Model TP 1803D: Current and Voltage accuracy are ± 2.5%

Battery: Battery Type: Lithium Polymer (LiPO Battery) C Rate: 70C Volts: 14.8 V Capacity: 6300mAh Cell Count: 4 S Cell Configuration: 4S1P Continuous Discharge: 70C (441A) Max Burst Rate: 80C (504A) Max Volts per Cell: 4.2 V Max Volts per Pack: 16.8 V Min Volts per Pack: 12 V Charge Rate: 1C (6.3A) Wire Gauge: 12 AWG Soft and Flexible Low Resistance Silicone Insulated Wire Plug Type: Venom UNI Plug. Compatible with Traxxas Plug, Tamiya Plug, Deans Plug & EC3 Plug. Dimensions: 137 x 46 x 46 mm / 5.4 x 1.8 x 1.8 in Watt Hours: 93.24 Weight: 20.5 oz (580 g)

Fan: (Spec. Sheet attached)

RL0503-5820-97-MS Thermistors: (Spec. Sheet attached)

NI myDAQ and myTEMP: (Spec. Sheet attached)

Descriptions:

1. Delta will not guarantee the performance of the products if the application condition fallsoutside the parameters set forth in the specification.

2. A written request should be submitted to Delta prior to approval if deviation from thisspecification is required.

3. Please exercise caution when handling fans. Damage may be caused when pressure is appliedto the impeller, if the fans are handled by the lead wires, or if the fans are hard-dropped to the production floor.

4. Except as pertains to some special designs, there is no guarantee that the products will be freefrom any such safety problems or failures as caused by the introduction of powder, droplets of water or encroachment of insect into the hub.

5. The above-mentioned conditions are representative of some unique examples and viewed as the first point of reference prior to all other information.

6. It is very important to establish the correct polarity before connecting the fan to the power source. Positive (+) and Negative (-). Damage may be caused to the fans if connection iswith reverse polarity, as there is no foolproof method to protect against such error.

7. Delta fans are not suitable where any corrosive fluids are introduced to their environment.

8. Please ensure all fans are stored according to the storage temperature limits specified. Do not store fans in a high humidity environment. We highly recommend performance testing is conducted before shipping, if the fans have been stored over 6 months.

9. Not all fans are provided with the Lock Rotor Protection feature. If you impair the rotation of the impeller for the fans that do not have this function, the performance of those fans will leadto failure.

10. Please be cautious when mounting the fan. Incorrect mounting of fans may cause excess resonance, vibration and subsequent noise.

11. It is important to consider safety when testing the fans. A suitable fan guard should be fitted to the fan to guard against any potential for personal injury.

12. Except where specifically stated, all tests are carried out at relative (ambient) temperature andhumidity conditions of 25oC, 65%. The test value is only for fan performance itself.

13. Be certain to connect an “over 4.7µF” capacitor to the fan externally when the application calls for using multiple fans in parallel, to avoid any unstable power.

SPECIFICATIONS

NI myDAQ

Analog InputNumber of channels.......................................... 2 differential or 1 stereo audio input

ADC resolution................................................. 16 bits

Maximum sampling rate ................................... 200 kS/s

Timing accuracy ............................................... 100 ppm of sample rate

Timing resolution.............................................. 10 ns

Range

Analog input ............................................. ±10 V, ±2 V, DC-coupled

Audio input ............................................... ±2 V, AC-coupled

Passband (-3 dB)

Analog input ............................................. DC to 400 kHz

Audio input ............................................... 1.5 Hz to 400 kHz

Connector type

Analog input ............................................. Screw terminals

Audio input ............................................... 3.5 mm stereo jack

Input type (audio input) .................................... Line-in or microphone

Microphone excitation (audio input) ................ 5.25 V through 10 kΩ

Absolute accuracy

Nominal Range

Typical at 23 °C (mV) Maximum (18 to 28 °C) (mV)Positive

Full ScaleNegative Full Scale

10 -10 22.8 38.9

2 -2 4.9 8.6

2 | ni.com | NI myDAQ specifications

Figure 1. Settling Time (10 V Range) versus Different Source Impedance

Figure 2. Settling Time (2 V Range) versus Different Source Impedance

200–0.25

0.25

0.5

0.75

1

1.25

1.5

1.75

2

2.25

2.5

3

3.25

3.5

3.75

4

0

180 160 140 120Sample Rate (kHz)

Set

tling

Err

or (

%)

100 80 60 40

2.75

2 kΩ5 kΩ10 kΩ

200–0.2

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

2.2

2.4

2.6

2.8

0

180 160 140 120Sample Rate (kHz)

Set

tling

Err

or (

%)

100 80 60 40

2 kΩ5 kΩ10 kΩ

NI myDAQ specifications | © National Instruments | 3

Input FIFO size ................................................. 4,095 samples, shared among channels used

Maximum working voltage for analoginputs (signal + common mode) ....................... ±10.5 V to AGND

Common-mode rejectionratio (CMRR) (DC to 60 Hz)............................ 70 dB

Input impedance

Device on

AI+ or AI- to AGND ........................ >10 GΩ || 100 pF

AI+ to AI- ......................................... >10 GΩ || 100 pF

Device off

AI+ or AI- to AGND ........................ 5 kΩ

AI+ to AI- ......................................... 10 kΩ

Anti-aliasing filter............................................. None

Overvoltage protectionAI+ or AI - to AGND ....................................... ±16 V

Overvoltage protection(audio input left and right)................................ None

Analog OutputNumber of channels.......................................... 2 ground-referenced or 1 stereo audio output

DAC resolution................................................. 16 bits

Maximum update rate ....................................... 200 kS/s

Range

Analog output ........................................... ±10 V, ±2 V, DC-coupled

Audio output ............................................. ±2 V, AC-coupled

Maximum output current(analog output)1 ................................................ 2 mA

Output impedance

Analog output ........................................... 1 Ω

Audio output ............................................. 120 Ω

Minimum load impedance(audio output) ................................................... 8 Ω

1 The total power available for the power supplies, analog outputs, and digital outputs is limited to 500 mW (typical)/100 mW (minimum). Refer to the Calculating Power Consumption section for information on calculating the total power consumption of the components of your system.


Connector type

Analog output ...........................................Screw terminals

Audio output .............................................3.5 mm stereo jack

AC-coupling high-pass frequency(audio output with 32 Ω load)...........................48 Hz

Absolute accuracy

Slew rate ...........................................................4 V/μs

Timing accuracy................................................100 ppm of sample rate

Timing resolution..............................................10 ns

Overdrive protection .........................................±16 V to AGND

Maximum power-on voltage1 ...........................±110 mV

Output FIFO size ..............................................8,191 samples, shared among channels used

Digital I/ONumber of lines ................................................8; DIO <0..7>

Direction control ...............................................Each line individually programmable as input or output

Update mode .....................................................Software-timed

Pull-down resistor .............................................75 kΩ

Logic level ........................................................5 V compatible LVTTL input; 3.3 V LVTTL output

VIH min .............................................................2.0 V

VIL max .............................................................0.8 V

Maximum output current per line2....................4 mA

Nominal Range

Typical at 23 °C (mV) Maximum (18 to 28 °C) (mV)Positive

Full ScaleNegative Full Scale

10 -10 19.6 42.8

2 -2 5.4 8.8

1 When powered on, the analog output signal is not defined until after USB configuration is complete.2 The total power available for the power supplies, analog outputs, and digital outputs is limited to 500 mW

(typical)/100 mW (minimum). Refer to the Calculating Power Consumption section for information on calculating the total power consumption of the components of your system.


General Purpose Counter/TimerNumber of counter/timers................................. 1

Resolution......................................................... 32 bits

Internal base clocks .......................................... 100 MHz

Base clock accuracy.......................................... 100 ppm

Maximum counting and pulsegeneration update rate....................................... 1 MS/s

Default routing

CTR 0 SOURCE....................................... PFI 0 routed through DIO 0

CTR 0 GATE ............................................ PFI 1 routed through DIO 1

CTR 0 AUX.............................................. PFI 2 routed through DIO 2

CTR 0 OUT .............................................. PFI 3 routed through DIO 3

FREQ OUT............................................... PFI 4 routed through DIO 4

Data transfers .................................................... Programmed I/O

Update mode..................................................... Software-timed

Digital MultimeterFunctions1 ......................................................... DC voltage, AC voltage, DC current,

AC current, resistance, diode, continuity

Isolation level ................................................... 60 VDC/20 Vrms, Measurement Category I

Caution Do not use this device for connection to signals or for measurements within Measurement Categories II, III, or IV. For more information on Measurement Categories, refer to the Safety Voltages section.

Connectivity...................................................... Banana jacks

Resolution......................................................... 3.5 digits

Input coupling................................................... DC (DC Voltage, DC Current, Resistance, Diode, Continuity);AC (AC Voltage, AC Current)

Voltage MeasurementDC ranges ......................................................... 200 mV, 2 V, 20 V, 60 V

AC ranges ......................................................... 200 mVrms, 2 Vrms, 20 Vrms

1 All AC specifications are based on sine wave RMS.


Note All AC voltage accuracy specifications apply to signal amplitudes greater than 5% of range.

Accuracy

Input impedance................................................10 MΩ

Current MeasurementDC ranges .........................................................20 mA, 200 mA, 1 A

AC ranges .........................................................20 mArms, 200 mArms, 1 Arms

Note All AC accuracy specifications within 20 mA and 200 mA ranges apply to signal amplitudes greater than 5% of range. All AC accuracy specifications within the 1 A range apply to signal amplitudes greater than 10% of range.

Function Range Resolution

Accuracy

± ([% of Reading] + Offset)

DC Volts 200.0 mV 0.1 mV 0.5% + 0.2 mV

2.000 V 0.001 V 0.5% + 2 mV

20.00 V 0.01 V 0.5% + 20 mV

60.0 V 0.1 V 0.5% + 200 mV

40 to 400 Hz 400 to 2,000 Hz

AC Volts 200.0 mV 0.1 mV 1.4% + 0.6 mV* —

2.000 V 0.001 V 1.4% + 0.005 V 5.4% + 0.005 V

20.00 V 0.01 V 1.5% + 0.05 V 5.5% + 0.05 V

* The accuracy for AC Volts 200.0 mV range is in the frequency range of 40 Hz to 100 Hz. For example, for a 10 V using the DC Volts function in the 20.00 V range, calculate the accuracy using the following equation:

10 V × 0.5% + 20 mV = 0.07 V


Accuracy

Input protection................................................. Internal ceramic fuse, 1.25 A 250 V, fast-acting, 5 × 20 mm, F 1.25A H 250V(Littelfuse part number 02161.25)

Resistance MeasurementRanges .............................................................. 200 Ω, 2 kΩ, 20 kΩ, 200 kΩ, 2 MΩ, 20 MΩ

Accuracy

Diode MeasurementRange ................................................................ 2 V


Accuracy


DC Amps 20.00 mA 0.01 mA 0.5% + 0.03 mA

200.0 mA 0.1 mA 0.5% + 0.3 mA

1.000 A 0.001 A 0.5% + 3 mA

40 to 400 Hz 400 to 2,000 Hz

AC Amps 20.00 mA 0.01 mA 1.4% + 0.06 mA 5% + 0.06 mA

200.0 mA 0.1 mA 1.5% + 0.8 mA 5% + 0.8 mA

1.000 A 0.001 A 1.6% + 6 mA 5% + 6 mA


Accuracy


Ω 200.0 Ω 0.1 Ω 0.8% + 0.3 Ω*

2.000 kΩ 0.001 kΩ 0.8% + 3 Ω

20.00 kΩ 0.01 kΩ 0.8% + 30 Ω

200.0 kΩ 0.1 kΩ 0.8% + 300 Ω

2.000 MΩ 0.001 MΩ 0.8% + 3 kΩ

20.00 MΩ 0.01 MΩ 1.5% + 50 kΩ

* Exclusive of lead wire resistance


Power Supplies

Caution Do not mix power from NI myDAQ with power from external power sources. When using external power, remove any connections to the power supply terminals on NI myDAQ.

+15V SupplyOutput voltage

Typical (no load) .......................................15.0 V

Maximum voltage with no load ................15.3 V

Minimum voltage with full load ...............14.0 V

Maximum output current1.................................32 mA

Maximum load capacitance ..............................470 μF

-15V SupplyOutput voltage

Typical (no load) .......................................-15.0 V

Maximum voltage with no load ................-15.3 V

Minimum voltage with full load ...............-14.0 V



+5V SupplyOutput voltage

Typical (no load) .......................................4.9 V

Maximum voltage with no load ................5.2 V

Minimum voltage with full load ...............4.0 V



Calculating Power ConsumptionThe total power available for the power supplies, analog outputs, and digital outputs is limited to 500 mW (typical)/100 mW (minimum). To calculate the total power consumption of the power supplies, multiply the output voltage by the load current for each voltage rail and sum them together. For digital output power consumption, multiply 3.3 V by the load current. For

1 The total power available for the power supplies, analog outputs, and digital outputs is limited to 500 mW (typical)/100 mW (minimum). Refer to the Calculating Power Consumption section for information on calculating the total power consumption of the components of your system.


analog output power consumption, multiply 15 V by the load current. Using audio output subtracts 100 mW from the total power budget.

For example, if you use 50 mA on +5 V, 2 mA on +15 V, 1 mA on -15 V, use four DIO lines to drive LEDs at 3 mA each, and have a 1 mA load on each AO channel, the total output power consumption is:

5 V × 50 mA = 250 mW

|+15 V| × 2 mA = 30 mW

|-15 V| × 1 mA = 15 mW

3.3 V × 3 mA × 4 = 39.6 mW

15 V × 1 mA × 2 = 30 mW

Total output power consumption = 250 mW + 30 mW + 15 mW + 39.6 mW + 30 mW = 364.6 mW

CommunicationBus interface ..................................................... USB 2.0 Hi-Speed

Physical CharacteristicsClean the hardware with a soft, nonmetallic brush. Make sure that the hardware is completely dry and free from contaminants before returning it to service.

Dimensions (without screw terminal connector)

NI myDAQ device part number 195509D-01L and earlier.......................... 14.6 cm × 8.7 cm × 2.2 cm

(5.75 in. × 3.43 in. × 0.87 in.)

NI myDAQ device part number 195509E-01L and later ............................. 13.6 cm × 8.8 cm × 2.4 cm

(5.36 in. × 3.48 in. × 0.95 in.)

Weight

NI myDAQ device part number 195509D-01L and earlier.......................... 175.0 g (6.1 oz)

NI myDAQ device part number 195509E-01L and later ............................. 164.0 g (5.8 oz)

Note NI myDAQ device part number (P/N: 195509x-01L) is located on the product label on the bottom of the device.

Screw-terminal wiring ...................................... 16 to 26 AWG

Torque for screw terminals ............................... 0.22-0.25 N · m (2.0-2.2 lb · in.)


EnvironmentalOperating temperature(IEC 60068-2-1 and IEC 60068-2-2)................0 to 45 °C

Storage temperature(IEC 60068-2-1 and IEC 60068-2-2)................-20 to 70 °C

Operating humidity(IEC 60068-2-56)..............................................10 to 90% RH, noncondensing

Storage humidity(IEC 60068-2-56)..............................................10 to 90% RH, noncondensing

Maximum altitude.............................................2,000 m (at 25 °C ambient temperature)

Pollution Degree (IEC 60664) ..........................2

Indoor use only.

Safety

Safety VoltagesMeasurement Category I1 is for measurements performed on circuits not directly connected to the electrical distribution system referred to as MAINS voltage. MAINS is a hazardous live electrical supply system that powers equipment. This category is for measurements of voltages from specially protected secondary circuits. Such voltage measurements include signal levels, special equipment, limited-energy parts of equipment, circuits powered by regulated low-voltage sources, and electronics.

Caution Do not use this module for connection to signals or for measurements within Measurement Categories II, III, or IV.

Safety StandardsThis product is designed to meet the requirements of the following standards of safety for electrical equipment for measurement, control, and laboratory use:

• IEC 61010-1, EN 61010-1

• UL 61010-1, CSA 61010-1

Note For UL and other safety certifications, refer to the product label or the Online Product Certification section.

Caution Using the NI myDAQ in a manner not described in this document may impair the protection the NI myDAQ provides.

1 Measurement Categories CAT I and CAT O are equivalent. These test and measurement circuits are not intended for direct connection to the MAINS building installations of Measurement Categories CAT II, CAT III, or CAT IV.


Hazardous LocationsThe NI myDAQ device is not certified for use in hazardous locations.

Electromagnetic CompatibilityThis product meets the requirements of the following EMC standards for electrical equipment for measurement, control, and laboratory use:

• EN 61326-1 (IEC 61326-1): Class B emissions; Basic immunity

• EN 55011 (CISPR 11): Group 1, Class B emissions

• EN 55022 (CISPR 22): Class B emissions

• EN 55024 (CISPR 24): Immunity

• AS/NZS CISPR 11: Group 1, Class B emissions

• AS/NZS CISPR 22: Class B emissions

• FCC 47 CFR Part 15B: Class B emissions

• ICES-001: Class B emissions

Note Group 1 equipment (per CISPR 11) is any industrial, scientific, or medical equipment that does not intentionally generate radio frequency energy for the treatment of material or inspection/analysis purposes.

Note For EMC declarations and certifications, refer to the Online Product Certification section.

CE ComplianceThis product meets the essential requirements of applicable European Directives as follows:

• 2006/95/EC; Low-Voltage Directive (safety)

• 2004/108/EC; Electromagnetic Compatibility Directive (EMC)

Online Product CertificationTo obtain product certifications and the Declaration of Conformity (DoC) for this product, visit ni.com/certification, search by model number or product line, and click the appropriate link in the Certification column.

Environmental ManagementNI is committed to designing and manufacturing products in an environmentally responsible manner. NI recognizes that eliminating certain hazardous substances from our products is beneficial to the environment and to NI customers.

© 2010–2014 National Instruments. All rights reserved.

373061F-01 Aug14

Refer to the NI Trademarks and Logo Guidelines at ni.com/trademarks for more information on National Instruments trademarks. Other product and company names mentioned herein are trademarks or trade names of their respective companies. For patents covering National Instruments products/technology, refer to the appropriate location: Help»Patents in your software, the patents.txt file on your media, or the National Instruments Patents Notice at ni.com/patents. You can find information about end-user license agreements (EULAs) and third-party legal notices in the readme file for your NI product. Refer to the Export Compliance Information at ni.com/legal/export-compliance for the National Instruments global trade compliance policy and how to obtain relevant HTS codes, ECCNs, and other import/export data. NI MAKES NO EXPRESS OR IMPLIED WARRANTIES AS TO THE ACCURACY OF THE INFORMATION CONTAINED HEREIN AND SHALL NOT BE LIABLE FOR ANY ERRORS. U.S. Government Customers: The data contained in this manual was developed at private expense and is subject to the applicable limited rights and restricted data rights as set forth in FAR 52.227-14s, DFAR 252.227-7014, and DFAR 252.227-7015.

For additional environmental information, refer to the Minimize Our Environmental Impact web page at ni.com/environment. This page contains the environmental regulations and directives with which NI complies, as well as other environmental information not included in this document.

Waste Electrical and Electronic Equipment (WEEE)EU Customers This symbol indicates that waste products must be disposed of separately from municipal household waste, according to Directive 2002/96/EC of the European Parliament and the Council on waste electrical and electronic equipment (WEEE). All products at the end of their life cycle must be sent to a WEEE collection and recycling center. Proper WEEE disposal reduces environmental impact and the risk to human health due to potentially hazardous substances used in such equipment. Your cooperation in proper WEEE disposal will contribute to the effective usage of natural resources. For information about the available collection and recycling scheme in a particular country, go to ni.com/citizenship/weee.

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National Instruments corporate headquarters is located at 11500 North Mopac Expressway, Austin, Texas, 78759-3504. National Instruments also has offices located around the world. For telephone support in the United States, create your service request at ni.com/support or dial 1 866 ASK MYNI (275 6964). For telephone support outside the United States, visit the Worldwide Offices section of ni.com/niglobal to access the branch office websites, which provide up-to-date contact information, support phone numbers, email addresses, and current events.

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