Deka HR3500ET UPS Instruction Manual

Deka HR3500ET UPS

DANGER: Lead Acid Battery Contains: Lead, Sulfuric Acid (Electralyte), Lead Compounds.

• Harmful if swallowed, inhaled, or in contact with skin.
• Acid causes severe skin burns and eye damage.
• It May damage fertility or the unborn child it ingested or inhaled.
• May cause harm to breastfed children.
• May cause cancer if ingested or inhaled.
• Causes skin irritation, and serious eye damage.
• Contact with internal components may cause irritation or severe burns.
• Causes damage to the central nervous system, blood, and kidneys through prolonged or repeated exposure if ingested or inhaled.
• Irritating to eyes, respiratory system, and skin.
• May form explosive air/gas mixture during charging.
• Extremely flammable gas (hydrogen). Explosive, fire, blast or projection hazard.
• Obtain special instructions before use.
• Do not handle until safety precautions have been read and understood.
• Wash thoroughly after handling.
• Do not eat drink or smoke when using this product
• Avoid contact during pregnancy/while nursing.
• Wear protective gloves/protective clothing, eye protection/face protection.
• Use only outdoors or in a well-ventilated area
• Avoid contact with internal acid.
• Do not breathe dustfumelgas/mist/vapors/spray.
• Keep away from heat/’sparks/open flames/hot surfaces. No smoking.
• IF SWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison center/doctor if you feel unwell.
• IF ON CLOTHING OR SKIN (or hair): Remove/Take off immediately all contaminated clothing and wash it before reuse. Rinse skin with water/shower.

PROPOSITION 65 WARNING: battery posts, terminals and related accessories contain lead and lead compounds, chemicals are known to the State of California to cause cancer and reproductive harm. Batteries also contain other chemicals known to the State of California to cause cancer. WASH HANDS AFTER HANDLING.

WARNING: Risk of fire, explosion or burns. Do not disassemble or incinerate. Not recommended for inverted use. Follow product charging instructions. High Voltage: Risk of shock. Do not touch uninsulated terminals or connectors.

Do Not Remove Vent Valve

BATTERIES AND OTHER RELATED PARTS CONTAIN LEAD

WARNING

• Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
• Batteries also contain other chemicals known to the State of California to cause cancer.

WASH HANDS AFTER HANDLING!

IN REFERENCE TO THIS MANUAL

• “Battery” is defined as an individual 12-volt unit.
• “Battery string” is defined as a series of connected electrical systems comprised of batteries (individual 12-volt units).

SAFETY PRECAUTIONS

Although all valve-regulated batteries have the electrolyte immobilized within the battery, the electrical hazard associated with batteries still exists. Work performed on these batteries should be done with the tools and the protective equipment listed below. VRLA battery installations should be supervised by personnel familiar with batteries and battery safety precautions.

WARNING: Risk of fire, explosion or burns. Do not disassemble, heat above 65°C, or incinerate.

Protective Equipment

Although VRLA batteries can vent or leak small amounts of electrolyte, electrical safety is the principle but not the only concern for safe handling. Per IEEE 1188 recommendations, the following minimum set of equipment for safe handling of the battery and protection of personnel shall be available:

1. Safety glasses with side shields, or goggles, or face shields as appropriate. (Consult application-specific requirements)
2. Electrically insulated gloves, appropriate for the installation.
3. Protective aprons and safety shoes.
4. Portable or stationary water facilities in the battery vicinity for rinsing eyes and skin in case of contact with acid electrolyte.
5. Class C fire extinguisher.
6. Acid neutralizing agent.
7. Adequately insulated tools (as defined by ASTM F1505 “Standard Specification for Insulated and Insulating Hand Tools”).
8. Lifting devices of adequate capacity, when required.

Procedures

The following safety procedures should be followed

Always wear safety glasses or face shields when working on or near batteries.

1. These batteries are sealed and contain no free electrolytes. Under normal operating conditions, they do not present any acid danger. However, if the battery case or cover is damaged, acid could be present. Sulfuric acid is harmful to the skin and eyes. Flush the affected area with water immediately and consult a physician if splashed in the eyes. Consult SDS for additional precautions and first aid measures. SDS sheets can be obtained at www.eastpennmanufacturing.com
2. Prohibit smoking and open flames, and avoid arcing in the immediate vicinity of the battery.
3. Do not wear metallic objects, such as jewelry, while working on batteries. Do not store un-insulated tools in pockets or tool belts while working in the vicinity of the battery.
4. Keep the top of the battery dry and clear of tools and other foreign objects.
5. Provide adequate ventilation (per IEEE standard 1187 and/or local codes) and follow recommended charging voltages.
6. Never remove or tamper with the pressure relief valves. Warranty void if vent valve is removed.
7. Inspect all flooring and lifting equipment for functional adequacy.
8. Adequately secure battery modules, racks, or cabinets to the floor.
9. Connect support structures to the ground system in accordance with applicable codes.
10. The below IEEE Standards contain additional information. Other standards may be relevant to your specific application.

• IEEE 1184: Guide for Batteries for UPS Systems
• IEEE 1187:  Recommended Practice for Installation Design of VRLA Batteries
• IEEE 1188: Recommended Practice for Maintenance, Testing, of VRLA Batteries
• IEEE 1189: Selection of VRLA Batteries for Stationary Applications

RECEIVING & STORAGE

Receiving Inspection

Upon receipt, and at the time of actual unloading, each package should be visually inspected for any possible damage or electrolyte leakage. If either the entire shipment should be conducted and noted on the bill of lading. Record receipt date, and inspection date and notify the carrier of any damage.

Unpacking

1. Always wear eye protection.
2. Check all batteries for visible defects such as cracked containers, loose terminal posts, or other unrepairable problems. Batteries with these defects must be replaced.
3. Check the contents of the packages against the packaging list. Report any missing parts or shipping damage to your East Penn agent or East Penn Mfg. Co. immediately.
4. Never lift batteries by the terminal posts.

Storage / Refresh

Batteries should be installed, and float charged upon delivery. If batteries are to be stored, the below requirements shall be followed.

1. Batteries shall be stored indoors in a clean, level, dry, cool location.
2. Store, charge, and ship in vertical position only.
3. Recommended storage temperature is 50°F (10°C) to 77°F (25°C). Acceptable storage temperature is 0°F (-18°C) to 90°F (32°C).
4. The batteries shall be given a refresh charge at regular intervals as detailed below: 0°F(-18°C) to 77°F (25°C) Batteries shall be charged by the“battery charge date” marked on a pallet. Successive recharges shall be performed every 6 months. 78°F (26°C) to 90°F (32°C) Battery voltage readings shall be taken monthly. Batteries must be given a refresh charge within 3 months from the date of receipt or if any battery voltage falls below 12.72 volts per battery, whichever occurs first. Successive refresh charges shall be performed every 3 months.
5. Whenever a refresh charge is required, it’s important that all batteries to be installed in the same series string and receive a charge at the same time to ensure continuity once placed in their intended application.
6. Each battery shall be charged for 24 hours at a constant voltage equal to 14.40 volts per battery. To ensure the batteries are fully charged within 24hrs, the charger used for this refresh charge must have the capacity to provide at least the minimum charge current specification and not exceed the maximum charge current for the given battery type (model), as called out in Appendix C.
7. All requested information on the “Refresh Record Form” in Appendix A should be completed for each refresh charge.
8. Batteries shall not be stored beyond 12 months. Storing beyond 12 months will affect the warranty.
9. If the storage/refresh requirements cannot be met, contact East Penn Reserve Power’s Product Support group for alternate instructions.

INSTALLATION

General

Caution should be taken when installing batteries to ensure no damage occurs. The battery string cabinet, tray, rack, etc. shall be inspected for sharp edges that could cause damage to the battery casing. Batteries shall not be dropped, slid, or placed on rough or uneven surfaces such as tray lips or grated flooring. Mishandling of batteries could result in equipment damage or human injury. East Penn will not be liable for damage or injury as a result of mishandling or
misuse of the product.

Grounding

When grounding the battery string, proper techniques should be applied per electrical standards such as NEC and/or Federal, State, and Local codes, as well as the User Manual of specific applications.

Cabinets

Cabinet systems come factory assembled and prewired. Do not tip or turn cabinets on their sides when positioning them in their intended installation area. Cabinets must be used in an upright position. These systems are pre- connected. Only inter-shelf, inter-cabinet and connections to the load are required. See the connection diagram inside the cabinet. Inter-cabinet and load connection cables are not included.

Racks

Assemble racks in accordance with the intended arrangement, align with a level and bolt to the floor. See rack assembly instructions.

DEKA FAHRENHEIT BATTERIES ARE TESTED AND APPROVED TO BE INSTALLED AND OPERATED IN THEIR UPRIGHT POSITION.

TOP TERMINAL BATTERY

FRONT TERMINAL BATTERY

FOR ANY OTHER INSTALLATION ORIENTATION, THE PRODUCT WILL NOT BE WARRANTED.

Venting

Under normal operation, VRLA batteries emit hydrogen gas, which is combustible at certain concentrations. Proper ventilation should be provided per IEEE 1187 and/or local codes. Some batteries are designed to accommodate the use of vent tubing. Ventilation equipment is not designed or supplied by East Penn Mfg. Safe installation of any venting equipment is the responsibility of the installer.

BATTERY ASSEMBLY

(ALWAYS WEAR EYE PROTECTION.)

1. Set up the battery string so that the positive post (+) of one battery is connected to the negative post (–) of the next battery for all series connections. The inter battery connector contact surfaces shall be cleaned by rubbing gently with a non-metallic brush or pad before installing connectors. Only approved oxide inhibitors (No-Ox-ID “A” from Sanchem, Inc.) may be applied to connections or battery posts.
2. For future identification, individual batteries should be numbered in an electrical connection sequence, beginning with number one (1) at the positive end of the battery string.
3. Install all inner battery connectors using lock washer and bolts loosely to allow for final alignment of batteries, then torque to 100 in-lb +/- 5. After torquing the connections on racked batteries, read the voltage of the battery string to assure that individual battery are connected correctly. The total voltage should be approximately equal to the number of batteries times the measured voltage of one battery (when connected in series). If the measurement is less, recheck the connections for proper voltage and polarity.
4. Read and record inner battery connection resistance and note the method of measurement. This helps determine a satisfactory initial installation and can be used as a reference for future maintenance requirements. See Battery Maintenance Report. (Pg. 10 – Appendix D ). Clean, remake and re-measure any connection having a resistance measurement greater than 10% of the average of all the same type of connections (inner battery, inter-tier or shelf, inter-rack or inter cabinet).
5. Battery performance is based on the output at the battery terminals. Therefore, the shortest electrical connections between the battery string and the operating equipment result in maximum total battery string performance.

Do not select cable size on current carrying capability only. Cable size should not provide a greater voltage drop between the battery system and operating equipment than specified. Excess voltage drop will reduce the desired support time of the battery system.

SYSTEM OPERATIONS

Charger Voltage

These batteries are designed for continuous float applications.

• FLOAT / STANDBY (per battery)
• 13.50V +/- 0.06 @ 77°F (25°C)

When setting the float voltage on the charger, the battery string should be set to float at the nominal battery float voltage times the number of batteries in the string. The charger must be able to maintain the system voltage within ± 0.5% of the desired level at all times. The desired float voltage varies with temperature. Consult Voltage Compensation Chart (Appendix B).

TEMPERATURE COMPENSATION

Battery voltage should be adjusted for ambient temperature variations.

• 12mV per °C (1.8°F) per 12V battery
• Consult Voltage Compensation Chart
• (Appendix B) for temperature compensation voltage maximum and minimum limits.

Charger Current

• Charge current should not exceed the recommended min. and max. requirements. Consult Appendix C for min. and max. charge current limits.

Battery Voltage

• Although the charger must maintain the system voltage within ± 0.5%, individual battery voltages may vary by ± 0.30V per battery of the average battery string float voltage.

Equalizing

Up on installation of the battery string, an optional charge of 14.40V per battery ± 0.06 @ 77°F (25°C) for 24 hours (not to exceed 24 hours) can be applied. (NOTE: Verify that the higher battery voltage will not adversely affect any other connected equipment). If this is done, be sure to reset the charging equipment to the proper float voltage.

Battery Operation

Battery operating temperature will affect battery string capacity and operating life. Temperatures greater than 95°F (35°C) will reduce the operating life of the battery. For every 19.8°F (11°C) increase in operating temperature above 95°F (35°C), the warranty period will be proportionally reduced by 50% as shown below:

Operating Temperature| Proportional Percentage (%) of Life
---|---
ºF| ºC
95º| 35º| 100%
100.4º| 38º| 80%
109.4º| 43º| 60%
114.8º| 46º| 50%

The battery string operating temperature should not exceed 140˚F (60˚°C). If operating temperatures are expected to be in excess of 140°F (60°C), contact East Penn for recommendations. Discharging at temperatures less than 77˚F (25˚C) will reduce the capacity of the battery. If operating temperatures are expected to be less than 50°F (10°C), contact East Penn for recommendations. The battery string must be located in a manner that the individual batteries do not vary by more than 5˚F (2.8˚C) between the lowest and highest individual battery temperatures.

Rectifier Ripple Voltage

FREQUENCY

A ripple that has a frequency greater than 667Hz (duration less than 1.5ms) is acceptable unless it is causing additional battery heating. A ripple that has a frequency less than 667Hz (duration greater than1.5ms), must meet the following voltage specification to be acceptable.

VOLTAGE SPECIFICATION

Ripple voltage shall be less than 0.5% peak to peak of the manufacturer’s recommended battery string voltage. Failure to comply can void the warranty.

RECORD KEEPING

Voltages, Temperatures & Ohmic

READINGS

Record keeping is an important part of stationary battery maintenance and warranty coverage. This information will help in establishing a life history of the battery string and inform the user if and when corrective action needs to be taken. Consult Battery Maintenance Report. (Pg. 10 – Appendix D). While it is acceptable to operate at temperatures less than 77°F (25°C), it will require a longer charging time to become fully recharged. Also, the capacity will be less at operating temperatures below 77°F (25°C). After installation and when the battery string has been on float charge for one week, the following data should be recorded:

1. Battery string voltage at battery terminals while the battery is on float charge.
2. Charger voltage at charger panel meter.
3. Individual battery float voltages.
4. Ambient temperatures within the area of the battery string.
5. Terminal connections should be checked to verify that the installer did torque all connections properly to 100 in-lb +/- 5. Micro-ohm readings should be taken across every connection. Refer to meter manufacturer’s instructions for proper placement of probes. If any reading differs by more than 20% from its initial installation value, re-torque the connection 100 in lb +/- 5. If the reading remains high, clean contact surfaces according to Step 1 under Battery Assembly. Failure to maintain proper records including information as detailed above may result in voiding any applicable warranty.

ACCEPTANCE TESTING

Each battery should be at 100% State of Charge prior to performing an acceptance test on the battery system. To ensure the batteries are fully charged the following charge schedule should be followed. Batteries should be charged at the equalization rate of 14.40 volts per battery for 24 hours. Temperature-compensated charging parameters shall be applied as detailed in the “Voltage Compensation Chart” in Appendix B of this manual. To ensure the batteries are fully charged within 24hrs; the charger used for this charge must have a current equal to the maximum charge current for the given battery type (model), as called out in Appendix C of this manual. If these requirements cannot be met, contact East Penn Reserve Power’s Product Support group for alternate instructions. Upon completion, the charge voltage should be lowered to the float voltage of 13.50 volts per battery for a minimum period of 72 hours. Reference: IEEE 1188-2005 Section 7.2 for additional acceptance test requirements. Upon completion of the above charge, the desired acceptance test can be performed.

NOTE: There shall be no discharges of any duration between the start of the equalization and the completion of the float period. If a discharge does occur, the charging regime detailed above shall be repeated.

Upon completion of the acceptance test, the battery system should be placed on float charge at 13.50 volts per battery to restore the battery to its’ rated capacity.
Batteries should not require an equalization charge once they have passed their initial acceptance test. Consult with East Penn Reserve Power’s Product Support group before performing additional equalizing charges on batteries that have successfully passed their initial acceptance test.

MAINTENANCE

Always wear eye protection when working on or near batteries. Keep sparks and open flames away from batteries at all times. Review “Safety Precautions”.

Annual Inspection

1. Conduct a visual inspection of each battery.
2. Record the battery string voltage at battery terminals while battery is on float charge.
3. Record the charger voltage at the charger panel meter.
4. Record the individual battery voltages. The accuracy of the DMM (Digital Multimeter) must be 0.05% (on dc scale) or better. The DMM must be calibrated to NIST traceable standards. Because float readings are affected by discharge and recharge, these readings must be taken when the battery string has been on a continuous, uninterrupted float for at least one month. The battery should be within ± 0.30 volts of the average battery string voltage.
5. Record the ambient temperatures.
6. Record the battery string temperature at the negative terminal.
7. Record individual battery Ohmic readings.
8. Record all inner battery and terminal connection resistances. Micro-ohm readings should be taken during this inspection. If any reading differs by more than 20% from the initial readings taken, retorque the connection. The resource value is equal to initial torque value as indicated in the BATTERY ASSEMBLY section. Recheck the micro-ohm reading. If the reading remains high, clean the contact surface according to the installation portion of this manual.
9. Other Maintenance Inspection intervals follow IEEE 1188.

Battery Cleaning

Do not use any chemical compounds to clean batteries. Batteries, cabinets, and racks shall only be cleaned with: clear water, a mixture of baking soda and water, or East Penn Mfg battery cleaner (part # 00321). Any other types of chemical compounds or solvents other than those listed above, to clean the battery may damage the battery case and/or cover causing possible exposure to sulfuric acid.

Capacity Testing

Per IEEE 1188 “Capacity testing is used to trend battery aging. The result of a capacity test is a calculation of the capacity of the battery. The calculated capacity is also used to determine if the battery requires replacement.” When performing capacity testing and recording data refer to IEEE 1188 recommendations.

NOTE: When discharging at higher rates, extra connectors may need to be added to prevent excessive voltage drop and/or excessive temperature rise. Should it be determined that only individual battery(ies) need to be replaced, contact East Penn?

APPENDIX A

| REFRESH RECORD FORM|
---|---|---
EPM Order **Number*| Pallet ID Number| Individual Performing Test (Full Name)| Date of Refresh| Refresh Duration**|
| | | | |

Model Number

| Information Prior to Refresh| Information within 1 hour of Refresh Completion| ****

Notes & Comments

|
Date Code| Battery Serial Number| ****

Open Circuit Voltage

| Battery Voltage Reading| Charging Current| Battery Temperature|
|
Battery 1| | | | | | | | |
Battery 2| | | | | | | | |
Battery 3| | | | | | | | |
Battery 4| | | | | | | | |
Battery 5| | | | | | | | |
Battery 6| | | | | | | | |
Battery 7| | | | | | | | |
Battery 8| | | | | | | | |
Battery 9| | | | | | | | |
Battery 10| | | | | | | | |
Battery 11| | | | | | | | |
Battery 12| | | | | | | | |
Battery 13| | | | | | | | |
Battery 14| | | | | | | | |
Battery 15| | | | | | | | |
Battery 16| | | | | | | | |
Battery 17| | | | | | | | |
Battery 18| | | | | | | | |
Battery 19| | | | | | | | |
Battery 20| | | | | | | | |
Battery 21| | | | | | | | |
Battery 22| | | | | | | | |
Battery 23| | | | | | | | |
Battery 24| | | | | | | | |

ALL FIELDS TO THE RIGHT OF THE CELL NUMBER ABOVE MUST BE COMPLETED EPM ORDER NUMBER WILL APPEAR ON THE SHIPPING LABEL ON THE CARTON COVERING EACH PALLET OF CELLS

TO ENSURE CONTINUATION OF WARRANTY, SUBMIT FORMS TO: East Penn Mfg. Co, Inc.,

Reserve Power Division, Product Support & Warranty Dept. ([email protected])
Form available as an Excel spreadsheet. Consult your EPM or Deka Services Representative.

APPENDIX B

VOLTAGE COMPENSATION CHART

APPENDIX C

DEKA FAHRENHEIT (LONG DURATION) CHARGE CURRENT LIMITS

Battery Type| Max. Charge

Current (A)

| Min. Charge

Current (A)

---|---|---
HT30| 5.5| 1.6
HT80ET| 13.1| 3.9
HT145ET| 26.0| 7.8
HT170ET| 30.4| 9.1
HT200ET| 36.4| 10.9
HT7500ET| 35.4| 10.6

= Using minimum charge current will extend recharge time and increase risk of battery being undercharged.

APPENDIX D

BATTERY MAINTENANCE REPORT

• Inspection Date: ___
• Company: ____
• Address: _____
• Battery location and/or number: __
• No. of Units/String: ___
• Type: ____
• Date New: ___
• Date Installed: ____

Individual Battery Readings

• Charger Output __ Amp
• Total Battery String Voltage_____
• Air Temperature___°F
• Panel Meter Volts___

Unit No.| Volts| Ohms or Mhos| Unit No.| Volts| Ohms or Mhos| Unit No.| Volts| Ohms or Mhos| Unit No.| Volts| Ohms or Mhos| Unit No.| Volts| Ohms or Mhos| Unit No.| Volts| Ohms or Mhos
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
1| | | 41| | | 81| | | 121| | | 161| | | 201| |
2| | | 42| | | 82| | | 122| | | 162| | | 202| |
3| | | 43| | | 83| | | 123| | | 163| | | 203| |
4| | | 44| | | 84| | | 124| | | 164| | | 204| |
5| | | 45| | | 85| | | 125| | | 165| | | 205| |
6| | | 46| | | 86| | | 126| | | 166| | | 206| |
7| | | 47| | | 87| | | 127| | | 167| | | 207| |
8| | | 48| | | 88| | | 128| | | 168| | | 208| |
9| | | 49| | | 89| | | 129| | | 169| | | 209| |
10| | | 50| | | 90| | | 130| | | 170| | | 210| |
11| | | 51| | | 91| | | 131| | | 171| | | 211| |
12| | | 52| | | 92| | | 132| | | 172| | | 212| |
13| | | 53| | | 93| | | 133| | | 173| | | 213| |
14| | | 54| | | 94| | | 134| | | 174| | | 214| |
15| | | 55| | | 95| | | 135| | | 175| | | 215| |
16| | | 56| | | 96| | | 136| | | 176| | | 216| |
17| | | 57| | | 97| | | 137| | | 177| | | 217| |
18| | | 58| | | 98| | | 138| | | 178| | | 218| |
19| | | 59| | | 99| | | 139| | | 179| | | 219| |
20| | | 60| | | 100| | | 140| | | 180| | | 220| |
21| | | 61| | | 101| | | 141| | | 181| | | 221| |
22| | | 62| | | 102| | | 142| | | 182| | | 222| |
23| | | 63| | | 103| | | 142| | | 183| | | 223| |
24| | | 64| | | 104| | | 144| | | 184| | | 224| |
25| | | 65| | | 105| | | 145| | | 185| | | 225| |
26| | | 66| | | 106| | | 146| | | 186| | | 226| |
27| | | 67| | | 107| | | 147| | | 187| | | 227| |
28| | | 68| | | 108| | | 148| | | 188| | | 228| |
29| | | 69| | | 109| | | 149| | | 189| | | 229| |
30| | | 70| | | 110| | | 150| | | 190| | | 230| |
31| | | 71| | | 111| | | 151| | | 191| | | 231| |
32| | | 72| | | 112| | | 152| | | 192| | | 232| |
33| | | 73| | | 113| | | 153| | | 193| | | 233| |
34| | | 74| | | 114| | | 154| | | 194| | | 234| |
35| | | 75| | | 115| | | 155| | | 195| | | 235| |
36| | | 76| | | 116| | | 156| | | 196| | | 236| |
37| | | 77| | | 117| | | 157| | | 197| | | 237| |
38| | | 78| | | 118| | | 158| | | 198| | | 238| |
39| | | 79| | | 119| | | 159| | | 199| | | 239| |
40| | | 80| | | 120| | | 160| | | 200| | | 240| |
Avg. Voltage| Avg. Voltage| Avg. Voltage| Avg. Voltage| Avg. Voltage| Avg. Voltage

e-mail: [email protected]

East Penn Manufacturing Co

• Lyon Station, PA 19536-0147
• Phone: 610-682-3263
• Fax: 610-682-4781
• www.dekabatteries.com
• E.P.M. Form No. 2100 11/21

© 2021 by EPM Printed in U.S.A.

All data is subject to change without notice. No part of this document may be copied or reproduced, electronically or mechanically, without written permission from the company.

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