A textbook demonstration of technical discipline that transforms a potentially hazardous high-current setup into a stable off-grid foundation. It effectively bridges the gap between DIY enthusiasm and professional-grade electrical safety through meticulous voltage matching and grounding.
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Deep Dive
First Time Charging 12 EG4 LL-S Batteries Using EG4 Chargeverter At 90 AMPS! | Off Grid Solar Build
Added:Welcome to Ridge Life. I'm Tim and today on the ridge, it's time it's time to charge our solar batteries for the very, very first time. Now, we're not going to be charging them from our solar panels today. We've got to get them all equalized, all topped out at 100%. That way, we can bring them on to the bus with our inverters. We have not yet commissioned our inverters. So, let's get the batteries charged up today. And how are we going to do it? We're going to do it with our EG4 100 amp charge verter. We're going to have a generator connected to the charge verter. Charge verter is going to then uh connect.
We'll probably do these batteries in groups. How long is it going to take?
Might take a while. Generator is really kicking. Oh, it went to 90. Oh, let me I hear that generator really. Let me go take that to I should have gone a little bit lower. Let me see here. We come inside our power shed here. You can see we got three EG4 6000XP inverters.
Everything is wired up and ready, but we have not yet commission them yet. We need to get our batteries charged. Now, we're going to charge them with this amazing little device down here. Again, this is the EG4 5 kowatt 100 amp charge verter. We've got it connected over here to our DC 600 amp bus. And those batteries are those bus that bus is connected to our batteries. And we have got two server racks full EG4 LLS. Six of them in this cabinet.
And then we've got six of them in this cabinet. Oo, guys, I am excited. Now, before we can charge these, we have to isolate them into uh I'm going to do banks of three. We got to make sure that the all three are within 0.5 volts of each other. And uh we also have to do some safety checks.
What safety checks? Let's find out.
First thing I want to do is uh check my uh DC bus. Make sure that the P plus and minus uh the positive and negative are isolated from each other. And also make sure neither of them are grounded. I also want for safety concerns want to make sure that all my cabinets are grounded. And we want to make sure they're grounded all the way back to the grounding electroconductor, that ground rod outside. So, first thing I'll do is take off this cover here, exposing our 600 amp bus. And positive. These are all the positive wires. Come over here.
These are all the negative wires.
Yeah, that looks beautiful. Now, I've got this uh Fluke multimeter here, and I'm going to put it on continuity. Okay, put it up on continuity. Pop this out.
Slide the uh positive cables there. All right. So now whenever I have continuity between this prong and this prong makes that noise. Okay. So let's start off making sure each cabinet is grounded to each other. Okay. We'll do that first. So all right. So the cabinets are grounded to each other. How about this cabinet to this cabinet?
That's good. Okay. All right. So, now let's check the uh positive bus to the negative bus.
It is not connected. That's good. That means nothing shorted between the positive and negative. I haven't mixed my wires up anywhere. That would be bad.
So, now let's check positive to ground.
Nothing.
And um I mean negative to ground should be nothing also because uh if if positive and negative weren't connected then the negative shouldn't be grounded either. So all right. So that looks good. So now we know that positive negative are ungrounded. The uh these two cabinets and these Oh, let's make sure these cabinets are both grounded.
They are. They're they're these are two separate cabinets right here. Now, let's make sure our cabinets, cuz we know that the uh ground wire going over the batteries is grounded to the cabinets.
Let's check the cabinets to the grounding electrode conductor. All right, we flipped it around. Here's our cabinet right here. And this copper solid copper six gauge uh wire goes down to our grounding electroconductor right below uh in the dirt out there. That's an 8 foot long copper clad um uh pole that's ground that's hammered all the way into the ground. So, um, me go to the screw right here and go to the copper. All right, we have a good Oh my gosh, that's a Let me check the screw here. Make sure. Oh, yeah.
Really good ground. That's about as low as it can go. All right, so now we know that we're grounded from our bus work, our 600 amp DC bus work that go to the batteries. Let's check the batteries out. Let's start in number two cabinet here. And uh each of these server racks um we have the negative bus bar over here, positive bus bar over here, and they've got little jumper cables that go from each one. But first, before we check all that, the the the grounds jumper, jumper, jumper, jumper to here, and then from here, they go down to the bottom over to the next cabinet, next cabinet, all the way around to the bus, bus to the ground electroconductor outside. So, let's check. We'll see if I can get it to reach the bottom one to the top battery. Second battery. Third, fourth, and fifth. All right. So now all the batteries now the top battery to the main cable. Main cable to the bottom.
Let's see. Actually bottom to the bottom. Okay. So that's good. Let's go into this cabinet here.
And the bottom to the Let's see here. We'll go to the bottom battery.
Okay. Bottom battery. Second.
There. There. There. There. And to the top. All right. So now we know that. Now we can go to the our electrode grounding electroconductor right here. Remember this copper wire coming up to the top.
We are grounded everywhere. So now we need to check our positive negative bus.
All right. Inside the cabinet here we got the positive on the left, negative on the right. The main cable comes in top right. Main cable comes in bottom left for positive and negative. Um all these little jumper wires go to the and again this is solid um or it's copper aluminum clad copper uh bus work on the side here. Um so the all the positive are on this bus work. All the negatives on the bus work. I've already you can visually see that. So what I'm going to do is let's check positive to negative again. I'm on continuity positive negative and it is open. So that means all the positives and all the negatives are open for every battery in this rack because they're all connected.
So now let's check positive to ground and negative to ground. And this cabinet should be good. The next cabinet should be good too because really all these positive negatives are connected to those. Everything is the same length from here to the bus work. So this positive goes all the way to the bus work over there. This negative goes all the way to the bus work over here. Same thing. All the cables are exactly the same length. Even for the inverter battery cables, all of them are exactly the same length. Even though we know these are all connected, just for giggles, we're going to check. So, positive to negative. Make sure that that still works. And then positive to ground, negative to ground. Let's just check our positive to the grounding electroconductor. Nothing. Negative to ground electroconductor. And one more time, ground to ground.
Yes, our meter doesn't lie. All right, this is our number one battery. Let's go ahead and turn the power on.
Number two, number three, number four, number five, and number six. All right, we can see state of charge lights all the way down. We can see 54. If I can get the to focus on it. Let's see here.
There we go. We can see we are 54% charge, 52.52 volts.
Let's check this one. There we go. 52.64 and then that one and then that one and then that one. Okay, so we are all close on all of these. That means I can actually um shut the output breakers on each of the uh each of them and connect them. But I'm not going to charge all 12 at the same time. I'm just going to charge three at a time. Now, we're going to do something I have never done yet on these batteries is turn them on and power this bus work. I've never actually had the output breakers on on any of these. Okay. And also, I'm not uh pre-charging the inverters right now.
The inverter battery breakers are open, so I don't have to worry about the uh proper sequencing of these um as far as the inverters go. So, don't worry about that. So, what I'm going to do is I'm going to uh well, check voltage on the bus work first. DC volts are zero. And in the manual, it says shut the output breaker and then turn the BMS on on the first unit. I'm just curious when I do this.
Well, that's kind of weird. I've got 7 volts DC coming out of there. Okay, let's turn on the uh BMS. See what happens.
All right, it's booting up and I have 52 volts and it says I've got 52.61.
So, that's good. So, let me go ahead and turn the BMS on on number two again.
Now, I'm going to parallel two batteries. It's kind of scary. And if I actually if I check, I'll see that I've got 52 volts on this one, right? Because they're they're paralleled through the bus work. So now here we go. 52.64 and uh let's see here. Um 52.61. So they're within 300s of each other. So I'll turn this on. They are now paralleled.
52.62 52.63 and 52 volts. All right. Same thing here. Number three.
Power it up.
All right, running. Shut this breaker.
And we should have 52 volts. And it was already 52.64. So they are within hundreds of each other.
So these three are now paralleled. Do we have voltage on our 600 amp bus? Let's go check it out. All right, let's check out our DC bus. Positive and negative.
And we've got 52 volts. That's exactly what I expected. So, now we got to get our generator ready and uh connect get it running, get it fueled up and uh connect it outside and then we'll come over here and power up our charge inverter for the first time. So, we can see we've got some temporary cables running down from our solar panels and they are powering our Jackary and our Blue Eddie over there. I do have these two generators here, a Predator inverter 8750 and a Predator Super Quiet Inverter 5000. Today, we're going to be using the 8750. Now, the good thing about the uh charge verter is you do not have to use an inverter generator to charge your batteries. You can actually keep it running on the system with the inverters running because the uh charge verts as an inverter for you. It's actually a rectifier. So, uh it it's it puts the clean in between your generator and your DC bus. So, we're going to use this um Vivore 48galon um gasoline pump. I got a battery right there. Let's get it connected. fill up our generator. Uh, my cable's a little bit short, so I got to pull it over and we'll get it running and connected.
Get our battery leads. Positive, negative.
There we go. Turn the pump on.
All right.
Filling up some There's some gas in it.
AIN'T GOT NO GAS IN IT. WELL, IT AIN'T GOT NO GAS IN IT.
There she goes. Woohoo. Fill her up.
Yeah, we are completely empty here.
Nice having that 48 gallon tank. I'll tell you that. I can't imagine being like a lot of the other off-grids having to go get gas every week for your generators. Now, I've been lucky. I haven't had to run my generators very much because I got the major uh solar array going to my Jackary 5000, my Bluey AC 240. Um, so but occasionally when I when I have to run air conditioner all night long and all day, I do have to uh supplement a little bit at night time with the generators and uh these predators, they've done a good job so far. I I definitely had don't have any complaints. Um especially with that Vivore 48 gallon uh gas tote. I mean, I've only had to fill it like three times now. That's pretty awesome.
Especially I got it when gas was cheap.
I got a gas WAS LIKE $3 A GALLON. ALL RIGHT. NO, IT WAS like 250, I think.
Uh-oh. Here we go. I think we're about full.
All right, we are topped off.
Turned off.
Battery disconnected.
Cleaned up and safe. All right, let's get this generator moved over a little closer. I need to get a little bit longer cable, that's for sure. All right, let's get it moved.
Get it primed.
Let that warm up just a little bit. Let me go get the cable, get it ran. That way, this thing's warmed up and ready to provide power.
I got a big muddy hole right here. I left this open. So, I still got to dig a trench over to where the house is going to be. This is just the solar shed. So, let me uh get this open.
Twist lock.
Twist locked in place.
Let's get this cable plugged in. Breaker is off.
Twist. All right. Now, I'm going to turn the breaker on. No current should be flowing because we're not plugged in on the inside. Let's go inside.
Wow.
All right. Now for the moment of truth.
Um I have the uh breaker is off for the uh output of the charge verter. So let me go ahead and plug it in and uh we'll see if we get some power up. Get this thing plugged in. Okay.
Look at there.
Look at there, guys. It's booting up.
Please wait. Please wait. Come in a little closer and I'll show you what I see. All right, there you go. Let's see if we can zoom in and you can see what I see.
She right there. There we go. 54 volts and uh zero amps. State of charge says lost because I do not have the um uh RS uh RJ45 RS 485 connection established.
Uh, but we can see we've got power and charge status. Excellent. If we look at this end of the charge ver, we can see an RS RJ45 connection right there.
There's actually two. The top silver one, that's for uh RS45 communications.
You can plug that into your host battery and uh then it will start and stop and regulate based on the voltage. And you can do state of charge. You can do state of you can do all kinds of things through your communications. The one below it is dry contact. You actually can regulate run and start and stop your generator with this when it's connected to the battery as well. That is pretty cool. So, we can see right here quick connects for the positive and negative going up. We got them going in there and then they come out and go down to our bus. All right, we are 54 volts.
Remember, our batteries are like 52.6.
So, um they uh they should charge. Uh if we go through the settings, let's see here. Let's go to enter. We can see our uh charge setting is 54 volts, state of charge start is 80%, battery start 43 volts. Uh current charge rate is 10 amps. Remember we can go up to 100 amps here. Um uh state of charge 90%. Is that right? And battery storage uh was that 54? It's hard for me to see with my eyes. Yeah, 54 volts. All right. So uh we're going to start with the 10 amp rate and see what happens. So let's escape out of here. We're not going to change any settings for now. Turn it on.
All right. Oh, I hear the generator move. 52.7 volts, 10.2 amps. So, we are charging at a two 52.8 volts, 10.2 amps. Let's check our um uh batteries and see if they're registering that current. Let's wake them up. Hit each of these buttons right here and we'll see if they're actually charging. Uh, all right. And that should it should evenly distribute the current between each three cuz all the cables are the same length. Everything's the same. So, let's come a little closer.
Let you see what the currents are.
Right. The top one is 3.24 amps.
The next one down 3.2428.
Yep. And the third one, let's see. Same thing. Yep. 3.33. So, all right, we are charging. I think we can charge a little bit faster than that. All right, we're still at 10 amps charging. Now, the EG4 LLS battery can charge at 100 amps, right? Um, preferably you want to uh charge them at 30 to 50 amps each for improved lifespan. So, right now, we're doing three amps to each one of them. So to get each one of them to 30, I got to raise this to 60. All right. So I'm going to hit a or enter.
And then I'm going to uh scroll to the uh charge current. Then I'm going to hit enter.
And I'm going to hit the down to go over to 10. And I got to increase this. What?
We said 30 for each be. So I have to go all the way to 90. Is that right? Let me just try a 40 first.
Hit enter.
And it takes it. Let's escape out and see if it goes up actually.
Okay. Oh, it reset. Yeah. So, it's starting to come back up now. 5 6 7 8 9. Is it going to come up that slowly?
Wow. 11. No. No. 11. Yeah, it comes. So, it rises it real slowly. So, knowing that, let me go ahead and go back to enter and I'll hit the uh I'll just go ahead hit the down arrow this time.
Scroll through like you said. I hit the current, hit enter, and I'm going to go down over. So, down makes you go over.
Up changes the number. So, I'm going to go to See, it said 90, right? Let's go 90. Can we get 90? We might not be able to get 90.
90. Hit enter. We are set. Oh, I heard the generator kick up. Woo. Let's go over here and see what we got. Okay, so now it's ramping back up.
Let's just watch it. See how fast it goes up to 90 five. All right, I'm not going to make you wait.
I'll be right back. All right, we can see we're charging about 12 or so amps on each of them.
We need to get up to 30.
Looks like we've stalled out at about 40 amps. And even though we've got it set to 90 amps. You see that right there? We are at 90 amps setting for the current.
Um, so what that probably means is I have to increase the charge voltage to get that current up. Um, I don't know if they actually tell you that in the manual, but we'll just try that right there. I'm going to go see down. I'm going to change that to 55 volts. You can go up to 57, I believe. Let me try 55. Hit enter. Oh, I hear the generate generator is really kicking. Oh, it went to 90. Oh, let me I hear that generator really. Let me go take that to I should have gone a little bit lower. Let me see here. Uh, enter. I'm going to go to 50.
Uh, four.
Can I read that? 54.5 4 5 enter. Okay, that sounds a lot better.
54.5.
Yeah, that's like 60 amps.
It's still going up. Let's see. Let's see how it go. I went straight to 90 when I did a whole voltage change.
Probably shouldn't have done one whole volt. Uh let's see where this stabilizes at.
Looks like that's stabilized at about 62. You guys are learning with me as I go here, too. It's my first time using it. So, uh if I make any mistakes, it's on my dime and not yours. So, let me uh change the uh charge voltage again. I got to get down here a little bit lower.
How low can you go? 54.5.
Enter.
Down. Down. I'm going to do uh 54.7.
Enter. I hear the generator come up a little bit.
Oh, the fan on the charge verter comes on.
That's what I heard's the fan. Oh, yeah.
The fan on the charge verters on. That's really cool. Yeah, there's some heat.
Let me fill the cables. I I I have a a Fluke temperature gun, but I I left it over at the at the farm. I wish I'd have had that, but nothing feels warm.
Battery cables don't feel warm. I'll check the bus and over there, but boy, this charge verter is putting out some heat now. Good thing I've got a EG4 mini split in here keeping the uh the shed cool here. All right, we are at 71 amps and it's stabilized. So, let me uh back back or go back in and uh let's see here.
Uh, enter. Down, down, down. 50.7.
I'll go 8.
There we go.
And now we're coming up 76 77.
All right. Okay. Let me go up a little bit more. Do this again.
54.9 54.9.
Now we're at 82.
82. So maybe 5.
That's where it should have been. I just did a giant jump. I don't know if I probably should have done that, but 50.
Let's go to 55. Back where I was going.
I'm 54.9 now. Oops. Let me go back.
Okay. So let's go to down 55 55 even.
We are at 90.8 amps. 90.8 amps.
55.1 volt. Let's see what uh we're charging over here on the batteries. All right.
28.8 8 30 and 30. I like it. 29.7 at the top one again. So, yeah, they're all at 30.
That's right where I want to keep them.
Do a slow charge. We'll see how long this takes.
So, again, I'll feel the cables over here.
The AC cables not warm. The DC cables are a little bit warm. Now, we come over here.
Oh, yeah. These these two watt are cold and the one out go to the inverters. So there's nothing. Yeah, don't the fan is going going wide out. Now I do have hardy backer board. I mounted this charge burner. I got good ventilation all around it. I do have a EG4 mini split in here. Um if you want to see the video of me mounting my EG4, that's a separate video. We'll go check that out.
It's in my solar playlist here on Ridgelite.
I know it's pretty loud in here. the generator outside. I can hear it. It's doing all it can. Uh this room is pretty well insulated. My battery uh shed. The uh charge burner is it's fan. That fan is kicking kick kicking like Vanam. Um but let me go ahead and go over to some of these tech specs with you real quick.
Okay. It is a 48vt nominal uh battery charger, but Tim, you're at 56 volts charging right now. It's nominal 48 volts. That's what it's called. Now, we are operating it at 240 volt. So, it can go up to a 100 amp charge. If you uh opt to use 120 volt now, it comes with a standard four-prong 30 amp uh 240 volt uh plug. You can convert that over to 120 if you want to just use uh that. But at 120, it'll only charge at 45 amps.
So, that's that's the half the current.
Um and then if you have 208 AC, it'll charge at 50 amps. um which is considerably less than 240. You know what I'm saying? Um but it uh the voltage range is 43 to 57 volts. We're at 56 volts right now. Um let's see here. Uh the max output it it can put out 5,120 watts, right? So I've got a 8750 W inverter generator powering it. So we should be okay at 240. Um, if you charge it at 120 uh volts, you can go up to 3,50 watts. So, 5,120 watts uh for 240 and 3,50 watts for 120. Um, and the max efficiency at 240 it's 94% efficient and at 120 it's only 92% efficient. Um, the AC input voltage range from 90 to two to 264. So there, you know, if you have a a non-inverter generator that moves up and down a little bit, it it it'll be okay.
50 to 60 Hz. Uh the max input current is 26 amps. Uh is on a 30 amp plug, 30 amp protection. Uh and that's at 240 and at 28 amps at 120. Uh when it's sitting idle, it uses about 10 watts. So that that's not too bad. That's not too bad.
Uh, you can operate this thing 14 to 131° F. Um, let's see. Make sure you watch your humidity, though. You don't want to keep a really, really humid environment. Uh, an altitude up to 400 and 4,921 ft. Wow. All right. Um, yeah, it does have uh the RS45 on a on the um RJ45 jack. And uh this thing weighs about 13 lbs, but it does come with a 3year warranty if it's used indoors. If you use this thing outdoors, you don't get that that 3year warranty. Now, let's go over some of the settings. Uh I I I'm not using the communications uh the RJ45 or the dry contact, so I really can't show you those, but I can go over some of the parameters. Uh again the uh the voltage the charging voltage uh I already showed you 43 to uh 57 volts I think uh was it 54 is the default uh they got the state of charge start that parameter uh the state of charge threshold is what that is uh battery start that's the uh battery under voltage threshold uh current of course that is the charging current we we change that the state of charge charge stop which that's the point at which it stops state of charge uh and the battery stop that is the battery over voltage threshold and you can see all the uh the texts uh in the manual for for all those. One last thing about the operation LCD we we talked about we showed you that while ago. Uh it does have those two LEDs the power LED uh when it is green solid um the unit is powered up. Um, whenever the charging LED, that's the other one. Uh, when it's green solid, that means your battery is fully charged. And when it's flashing, the battery is currently in the charging state. All right. Our batteries are about 70% charged right now. So, I'm calculating about 2 hours per set, right? Set of three. Cuz we got um 61,000 W hours of batteries. They were about a little over half charged.
So that's about 30,000 W hours I had to charge. I'm charging about a 45 4600 watt rate uh with the generator out there at 90 amps. So again, I'm thinking about hour and 3/4 2 or 2 hours at the most to get up to 100%. And then when that happens, I'll um disconnect, switch over to the next set of three, start them up, get them up to 90 amps, do that for about 2 hours. So we got a little bit to do. So, I'll be back. All right, we are 100% charged now on our first three batteries. And look at the current. It is dropping like a rock. 23.
Uh let's see what we got. 18.75.
And uh that one is very very low also.
So, let's see what the charge uh total current is now that uh everything is ramping down. So, we were at 90 amps.
Now, we're at what 57 or so. So, it's just slowly coming down.
I'm think I'm going to just let it uh top off just a little bit more and then we'll move on to the next three.
Currently, we'll continue to keep going down and down. I don't have time.
They're all at 100%. Those three are I got nine more batteries to charge, right? So, it really doesn't say this in the shutdown procedure. Basically, just says disconnect the DC and then disconnect the AC. I'm going to change the charge current back down from 90 amps to 10 amps. That way, next time I start it up, it'll be at 10 amps.
doesn't really say you got to do that, but that's what I'm going to do. So, let's see here. Let's do the uh enter uh down. So, up up enter.
And then that goes There we go. Dropped out. Turn the DC breaker off. Now I can go over here and uh swap these three. Take the next three on. same procedure I did last time to bring the the first three on. So, all right, let me get the next six or nine going and I'll meet you back when we're finishing up on the 12th battery.
All right, we have reached 100% on the last three of our EG4 LLS batteries.
Took about 7 hours. So, what we're going to do now is go ahead start the first three up. We're going to start all 12 of them up. Let them kind of top equalize.
So, let's go ahead and do that now. Let me go ahead and start this one. Probably hear the generator pick up just a little bit. Don't hear the fan on the uh EG4.
As the power goes down, the fan slows down. That's really nice cuz those things can be kind of loud, right? So, number one, and don't forget when you're starting up your uh EG4 LS batteries, you turn the output breaker on, wait 5 seconds, hit the BMS onoff switch, do the next always start with the host. I mean, we already had these going, but always start with the host. When you're shutting them off, do the same thing in reverse. Hit the BMS onoff switch, which kills the control power. Then wait 5 seconds and turn off the uh output breaker. I can hear them powering up now. Everything is coming in um nicely.
So, I'm going to go ahead and wait to 5 seconds, do all of these, and um we'll see what happens with the current and watch them all come down because they're all 100%. So, we'll just uh they'll equalize the top. This is exciting, guys. I I am super excited. So, we were at 90 amps and you can see it is uh coming down. What's that? 50 amps now.
It's going down. Just keeps going down.
Was that 60 or 50? It's hard to tell from my angle. 40. Yeah. So, it's So, it's going down. It's get Everything's getting very very quiet. So, let's check out over here. Um, all the batteries are on. All of them have their full state of charge lights lit. And if I look at the current, we'll see when these things power up.
Currents three, one amp on this one.
This one is zero. So, this one's fully topped off. Let's see the next ones.
How they look. And they all should start equalizing.
Uh, three.
Was that four 47? Uh, yeah. So, they are all starting to uh top off, equalize, and that makes me super happy. The the other six on the other side are doing the same thing. Now that the batteries are all topped up, I uh got them all secured, hit the BMS battery m uh management system button, waited a couple sec, few five seconds, turned off the output breaker, did that for all 12, starting with number 12, working my way to the host number one. Got the uh charge verter all secured. Got the generator cooled down, cable removed.
Everything is ready. We are ready to commission our three EG4 6000 XP inverters. Well, almost ready. I still have to get the rest of the solar panels wired up. If you guys remember, I did uh the last two strings on that third column. I got those. Everything's perfect to inverter number three. But for uh inverters number one and two, I'm still using those to my Jackaryi and my Blue Eddie to power the off-grid property here. So, I've got to get up there, take down all those uh temporary wires, wire all the uh strings in series, get them uh connected to their PV disconnect, get all that prettied up, and then we'll be ready to commission the final final step. Oh my goodness, we are so close. We are so close. So, if you like today's video, give it a big old thumbs up, like, share, and subscribe. It's always 100% free. Hit that notification bell right down there to be notified anytime a new video comes out on one of our channels. And as always, I hope everyone has a blessed, blessed day. And go ridgelife. Woo!
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