Test Procedure - iac.es · Test Procedure System AIV Procedure Code: SUN-IMaX-PR-GEN-005 Iss/Rv:...

Test Procedure

TITLE

System AIV Procedure

Code : SUN-IMaX-PR-GEN-005 Issue/Rev : Draft3 Date : 23/Apr/07 No. of pages : 22 Config. Doc. : Yes/No

IMaX – A Magnetograph for SUNRISE http://www.iac.es/proyect/IMaX

Test Procedure


Code: SUN-IMaX-PR-GEN-005Iss/Rv: Draft3 Date: 23/Apr/07 Page: 2 of 22

Approval control

Prepared by Luis González Juan Carlos González

INTA IAC

Revised by <name(s)> <institute>

Approved by <PI sub-project> Lieselotte Jochum

<institute> IAC

Authorized by Valentín Martínez Date:

IAC

IMaX is a joint development by a consortium of four institutions

Instituto de Astrofïsica de Canarias (IAC) Instituto de Astrofísica de Andalucía (IAA)

Instituto Nacional de Técnica Aeroespacial (INTA) Grupo de Astronomía y Ciencias del Espacio (GACE)

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Changes record

Issue Date Section Page Change description

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Applicable documents

Nº Document title Code Issue AD1 IMaX AIV Plan SUN-IMaX-PL-GEN-001 2A AD2 System Test Plan SUN-IMaX-PL-GEN-002 AD3 IMaX Requirements SUN-IMaX-SP-GEN-001 2C AD4 Verification Master Document TBD Reference documents

Nº Document title Code Issue

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List of acronyms and abbreviations He-Ne Helium Neon laser

IMaX Imaging Magnetograph eXperiment

LDM Long Distance Microscope

MTF Modulation Transfer Function

PCMM Portable Control Metrology Machine

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CONTENTS

1 SUMMARY ...............................................................................................................7

2 INTRODUCTION ....................................................................................................7

3 DEFINITIONS ..........................................................................................................7

4 AIV STAGE 2 METHODOLOGY..........................................................................7

5 STAGE 2 TASKS SEQUENCE...............................................................................9

6 DETAILED DESCRIPTION OF STAGE 2 TASKS.............................................9

7 FACILITIES, EQUIPMENT AND TOOLS ........................................................17 7.1 OGSE (OPTICAL GROUND SUPPORT EQUIPMENT)..................................................17

7.1.1 Clean Room Area Laboratory.........................................................................17 7.2 EGSE (ELECTRICAL GROUND SUPPORT EQUIPMENT) ............................................21 7.3 SGSE (SOFTWARE GROUND SUPPORT EQUIPMENT)...............................................21

8 ANNEX 1. VERIFICATION OF THE SYSTEM REQUIREMENTS DURING AIV STAGE 1 ................................................................................................................22

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Summary

Introduction According to document IMaX AIV Plan (AD1), from the first acceptance tests at unit level until the mission flight of SUNRISE, IMaX will be submitted to the following stages:

1. IMaX unit and subsystem AIV (IMaX subsystem level)

2. IMaX system AIV (IMaX system level)

3. SUNRISE subsystem AIV (IMaX meets the SUNRISE PFU and the telescope, SUNRISE subsystem level)

4. SUNRISE system AIV (Fully integrated PFU with telescope meets the gondola, SUNRISE system level)

Only stages 1 and 2 are considered as the IMaX AIV. The IMaX project team must of course contribute its part to stages 3 and 4 but the plan for such support is to be defined in close collaboration with the SUNRISE project office and under its responsibility.

Once the stage 1 has finished, i.e., once the individual subsystems have been accepted and delivered by the subprojects, the AIV stage 2 will consist of the integration and verification of them in order to get the complete system as a whole. It is important to remark that the individual subsystems will not go into stage 2 while the corresponding tests defined in their test procedures are not completely finished and accepted.

The present document refers only to the AIV stage 2.

Definitions

aiv STAGE 2 methodology The AIV stage 2 will consist of the several phases combining assembly, integration and verification work. Each of these phases will increment the functionality of IMaX as a whole system.

Section 0 shows the flow diagram of the AIV stage 2 tasks. Section 0 contains a table describing the different tasks.

The Assembly and Integration tasks will be described in the corresponding Integration Procedure that is referenced in the table of section 0.

Regarding the system verification a System Test Plan (AD2) is produced summarizing the tests to be done for IMaX validation. These tests will be oriented to verify IMaX science functionality rather than individual subsystems. Each of these tests will be described in detail by the corresponding test procedure, which also will include the detail criteria for validation. Also, there will be additional test procedure documents

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describing the rest of the test to carry out during AIV, to be produced by the task responsible. Those test procedures are referenced in the table of section 0.

The verification method for each system requirement is indicated in the verification matrix at the end of IMaX Requirements (AD3). Some of these system requirements will be verified as a part of any particular subsystem verification (i.e., during AIV stage 1), meanwhile in the rest of the cases will be verified as a part of the system verification (i.e., during AIV stage 2, in most of the cases during the last phase of stage 2). The table of section 0 indicates on which particular IMaX AIV stage 2 task each system requirement is verified. Also, Annex 1 shows those system requirements to be verified during AIV stage 1.

In any case, verification shall be accomplished by one or more of the following verification methods:

1. Test (T): When requirements have to be verified by measuring product performance and functionality. The analysis of data derived from test shall be considered an integral part of the test.

2. Demonstration (D): Can be considered as test where qualitative operational performance and requirements are demonstrated.

3. Analysis (A): When verification is achieved by performing theoretical o empirical evaluation by accepted techniques, the method shall be referred to as “Analysis”. An example is the modelling and computational simulation.

4. Inspection (I): When verification is achieved by visual determination of physical characteristics (such as construction features, hardware conformance to document drawings, etc) the method shall be referred to as “Inspection”.

The IMaX verification will be controlled by means of a Verification Master Document (AD4). This document will contain as a minimum:

• All IMaX requirements contained in AD3.

• The verification method assigned to each requirement

• The level (system, subsystem, unit) and the AIV Master Schedule task on which each requirement will be verified

• Site and responsible person of the verification

• Reference to the corresponding Test Plan

• Reference to the corresponding Test Procedure

• The verification result, showing formal compliance to the requirements (or non-conformance)

It is mandatory that all verification activities executing test procedures start and end with a team briefing of all participating personnel to check that everything is prepared for carrying out the test and to summarize and comment the results, respectively.

Also, a log book registering all the actuations on IMaX during AIV tasks shall be filled. Each task responsible shall be in charge of writing down the relevant actuations on the system under the corresponding task. In this way, the participants in the next tasks will

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be able to know the operations performed on the system. The information to be registered shall be at least date, hour and description of the operation. The log book shall be always near the system and consequently, shall be moved with it when needed.

STAGE 2 tasks sequence Enumeración de la secuencia de tareas de la fase 1 (como referencia para facilitar la visión de conjunto de la totalidad de AIV) y de la fase 2, con ayuda de un diagrama de flujo. La numeración de las tareas será la misma que la del AIV Master Schedule. Este diagrama (en lo que respecta a la fase 2) incluirá los puntos de control y verificación de requerimientos.

detailed description of STAGE 2 tasks Following a table containing the description of the stage 2 tasks is presented. The information included is as follows:

• Number of task: consecutive number starting at 1

• Code of the AIV Master Schedule activity that the task corresponds to

• Brief task description

• Facilities where the task will be performed

• Equipment and tools to be used (with reference to section 0)

• Responsible institution

• Task duration

• Comments: any Integration Procedure, Test Procedure or whatever document being applicable or as a reference for the task, shall be indicated in this field. Also, any other relevant comment should be included here.

El siguiente código de colores indica quiénes tienen que proporcionar la información que falta. No olvidar referenciar en el campo “Comments” los Integration Procedure, Test Procedure u otros documentos aplicables o de referencia, así como los requerimientos que se verifican en cada tarea:

IAC

INTA

IAA

GACE

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Code: SUN-IMaX-PR-GEN-005 Iss/Rv: Draft3 Date: 23/Apr/07 Page: 10 of 22

Nº AIV Code Description Facilities Support

Equipment Institution Days Comments

1 4.1.1 Subsystems footprint verification Clean Room (LINES)

Optical cube, theodolite,

PCMM

INTA 0,5 Verify footprint areas finishing and paralelism. Ref. Doc. Opto-mech integration

2 4.1.1 Alignment cube location Clean Room (LINES)

Theodolite, PCMM, He-Ne

INTA 1 Location to be confirmed. Ref. Doc. Opto-mech integration

3 4.1.1 Opto-mechanical supports mounting and centring

Clean Room (LINES)

Mech tools, theodolite, LDM,

He-Ne

INTA 4,5 Mechanical components are brought to the optical bench and aligned. Ref. Doc. Opto-mech integration

4 4.1.2 Optics mounting Clean Room (LINES)

None INTA 6 Optics is mounted. Ref. Doc. Opto-mech integration

5 4.1.3 Etalon mounting Clean Room (LINES)

None INTA 3 Etalon is mounted without starting-up

6 4.1.4 Collimation channel adjustment Clean Room (LINES)

Interferometer, Mech tools,

PCMM

INTA 3 Collimation channel is adjusted and verified. Requirement verification 5.2.3 Length of collimated beam Ref. Doc. Opto-mech integration

7 4.1.4 Camera channel adjustment w/o cameras Clean Room (LINES)

Interferometer Mech tools

INTA 3 Camera channel is adjusted and aligned. Ref. Doc. Opto-mech integration

8 4.1.4 Phase diversity mechanism mounting Clean Room (LINES)

Interferometer, theodolite

INTA 1 Phase diversity mechanism is mounted and focal plane 2 is mechanically referenced.

9 4.1.4 IMaX optical characterization Clean Room Target, Xe lamp, INTA 3 Requirements verification:

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(LINES) MTF test bench 5.1.1.6 Field of view 5.2.11 Collimated beam prop. 5.2.12 Telecentricity

10 4.1.5 PEE integration in Optical Bench Clean Room (LINES)

IAA 2

11 4.1.6 Optical enclosure harness integration on Optical Bench

Clean Room (LINES)

IAA 5 Entre los pasos 10 y 16 debe incluirse la verificación de los siguientes requistos de IMaX: 5.3.3.5 Bonding 5.3.5.3 Electrical power required 5.4.3.5 Grounding 5.4.5.3 Peak current 5.4.6.5 Uncertainties and Flight Predictions 5.5.2.6 Bonding 5.5.3.1 Structure 5.5.3.9 Bonding 5.6.7.1 Power input from SUNRISE 5.6.7.2 Current Limit 5.6.7.3 Grounding Requirements 5.6.7.5 IMaX internal power distribution 5.6.7.6 Power-On current limit 5.8.2.3 Telemetries 5.8.2.4 Mass Storage 5.8.3.1 Power supply 5.9.2 Mechanical interface 5.9.3 Electrical interface 5.9.5 Thermal interface 5.10.1 Environmental conditions

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12 4.1.7 ME-PE integration by main harness Clean Room (LINES)

IAA 1

13 4.1.8 Cameras and related harness integration Clean Room (LINES)

IAA 1

14 4.1.9 ICU simulator PC + EGSE PC integration

Clean Room (LINES)

IAA/IAC 1

15 4.1.10 Tests after ME, PE, Cameras & harness integration

Clean Room (LINES)

IAA 5

16 4.1.11 Etalon start-up Clean Room (LINES)

IAC 3

17 4.1.12 Camera 1 focus setting Clean Room (LINES)

Xe Lamp, Target, LDM, PCMM, EGSE

INTA 5 Camera 1 is mounted and aligned. Ref. Doc. Opto-mech integration

18 4.1.13 Camera 2 focus setting Clean Room (LINES)

Xe Lamp, Target, LDM, PCMM, EGSE

INTA 5 Camera 2 is mounted and aligned. Ref. Doc. Opto-mech integration

19 4.1.14 Transportation and conditioning on MTF test bench

Clean Room (LINES)

None INTA 2 MTF test bench shall be conditioned to receive IMaX

20 4.1.14 IMaX electro-optical characterization Clean Room (LINES)

Target, Xe-Lamp, MTF test

bench, EGSE

INTA 13 Requirements verification: 5.1.1.7 Spatial resolution 5.1.1.10 OTF measurement 5.2.9 Image quality 5.2.10 Image scale Ref. Doc. IMaX electro-optical test procedure.

21 4.1.15 Ghost images analysis Clean Room (LINES)

Target, Xe-Lamp, MTF test

INTA 3 Adjust etalon inclination to minimize retro-reflections effect.

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bench, EGSE Ref. Doc. Ghost images Test Procedure

22 4.1.16 External thermopars & related harness integration

Clean Room (LINES)

INTA 4

23 4.2.1 Focus compensation for vacuum operation

Clean Room (LINES)

Target, Xe-Lamp, MTF bench, EGSE

INTA 2 Change F4 support orientation and check defocus

24 4.2.2 PEE & MEE pressurization Clean Room (LINES)

INTA/GACE 1

25 4.2.3.1 Transportation to TVC Clean Room (LINES)

INTA 1

26 4.2.3.1 Set-up inside TVC Clean Room (LINES)

Target, Lamp (TBD), EGSE

INTA 4 Thermal Vacuum Chamber shall be conditioned to receive IMaX. Ref. Doc. IMaX Quality Test procedure at vacuum conditions without pre-filter.

27 4.2.3.2 Baking Clean Room (LINES)

INTA 3

28 4.2.3.3.1

System verification – image quality Clean Room (LINES)

Target, Lamp (TBD), EGSE

INTA 15 Reduced image quality test. Ref. Doc. IMaX Quality Test procedure at vacuum conditions without pre-filter.

29 4.2.3.3.2

System verification – thermal behaviour Clean Room (LINES)

INTA 7 Requirements verification: 5.4.2.2 Temperature Ranges and Stability 5.4.3.9 Heaters power density 5.4.6.3 Thermal Model and

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Equipment Institution Days Comments Verification Ref. Doc. Thermal behaviour Test Procedure.

30 4.3.1 Transportation and conditioning on test bench

Clean Room (LINES)

None INTA 3 IMaX comes back to the optical test table.

31 4.3.2 Pre-filter integration Clean Room (LINES)

Theodolite INTA 2 Replace pre-filter dummy with flight unit.

32 4.3.3 End-to-end illumination set-up Clean Room (LINES)

Target, Xe Lamp, EGSE

INTA 5 Illumination module preparation for end-to-end tests.

33 4.3.4 End-to-end spectral tests Clean Room (LINES)

IAC/INTA 7 Ref. Doc. End-to-end Spectral Tests Procedure

34 4.3.5 End-to-end polarization tests Clean Room (LINES)

IAC/INTA 7 Requirements verification: 5.1.1.8 S/N Ratio 5.1.1.9 Intensity crosstalk 5.1.2.1 Vector magnetograph 5.1.2.2 Longitudinal magnetograph 5.1.2.4 Vector spectropolarimeter 5.1.2.5 Longitudinal spectropolarimeter 5.1.2.6 Deep Magnetograph Ref. Doc. End-to-end test procedure. Ref. Doc. End-to-end Polarization Test Procedure

35 4.3.6 Etalon & ROCLIs calibration Clean Room (LINES)

IAC/INTA 2 Ref. Doc. Etalon & ROCLI Calibration Procedure

36 4.3.7 End-to-end image quality tests Clean Room (LINES)

Target, Xe Lamp,

IAC/INTA 7 Requirements verification: 5.1.1.4 Spectral resolution 5.1.1.5 Spectral scan

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EGSE 5.2.4 Wavelength range Ref. Doc. End-to-end test procedure.

37 4.3.8 Optical bench cover structure integration Clean Room (LINES)

INTA/GACE 3

38 4.3.9 Radiator integration Clean Room (LINES)

INTA 3

39 4.3.10 Optical bench cover walls integration Clean Room (LINES)

INTA/GACE 3

40 4.3.11 Thermal isolator mounting Clean Room (LINES)

INTA 5

41 4.3.12 End-to-end test Clean Room (LINES)

IAC/INTA 5 Ref. Doc. End-to-end test procedure.

42 4.4.1 Transportation to Test Facilities Test Facilities

INTA 1

43 4.4.1 Physical properties tests Test Facilities

Mass test tools, end-to-end equipment

INTA 4 Requirements Verification: 5.1.4.4 Mass To be confirmed if Center of Gravity will be tested as well. Includes an end-to-end test after test. Ref. Doc. Physical properties Test Procedure

44 4.4.2 Transportation to Vibration Test Facilities

Test Facilities

INTA 1

45 4.4.2 Vibration tests Test Facilities

Vibration tools, end-to-end

INTA 4 Includes an end-to-end test after test.

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equipment Ref. Doc. Vibration Test Procedure

46 4.4.3 Transportation to Thermal Test Facilities Test Facilities

INTA 1

47 4.4.3 Thermal Test Test Facilities

Thermal test tools, end-to-end

equipment

INTA 9 Includes an end-to-end test after test. Ref. Doc. Thermal Test Procedure

48 4.4.4 End-to-end acceptance test Test Facilities

End-to-end equipment.

IAC/INTA 5 Ref. Doc. End-to-end test procedure.

49 4.5 Storaging IMaX in transportation container

Test Facilities

ALL 2

50 5 IMaX ready for delivery to SUNRISE Test Facilities

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facilities, equipment and tools 1.1 OGSE (Optical Ground Support Equipment)

1.1.1 Clean Room Area Laboratory The features foreseen in the clean room and its main instrumentation are the following:

• Clean room area (LINES) 10000 class, surface 45 m2. Includes a thermal vacuum chamber, three optical tables and main instrumentation for optical integration and characterization.

• Visible and IR MTF Test benches Equipment for testing the optical quality of optical systems by means the Modulation Transfer Function (MTF). A light line is projected on the optical system and analyzing the image of the Line Transfer Function is obtained the Optical Transfer Function (OTF), which module corresponds the MTF. The optical bench offers the possibility to work in the IR wavelength bands 3-5 micron and 8–12 micron, using for this an IR illumination source and a IR mono-element detector cooled by liquid nitrogen. Both finite and infinite conjugate systems can be tested. The MTF is presented in real time.

• Theodolites This Instrument allows the measurement of horizontal and vertical angles with very high precision. The equipment let to measure the optical axis of instruments with respect to the mechanical axis with precision lower than 0.5 arcsec. INTA has various theodolites Leica T3000 and various Toal-station (with rangefinder and automatically controlled) and has great experience in working with this equipment in triangulation to obtain high precision axial measurements.

Figure 1. Theodolite Leica T3000

• Autocollimator The autocollimator is similar to the theodolite but has a higher optical aperture and focal length allowing a more easy location of the reflected beam through complicated windows or poor illuminated conditions. The equipment is easily

Test Procedure



combined with the theodolites assuring a very compact equipment. The Nikon 6D autocollimator provides an exceptional accuracy and reliability required for demanding measurements such as checking parallelism of end surfaces, squareness, flatness of surface plates, straightness of movement and calibration of rotary stages. The typical specifications are:

• Telescope Magnification:38x

• Objective: f=300mm; effective aperture: 70mm

• Measuring Range: 30 minutes of arc.

• Minimum Reading: 0.5 seconds of arc.

• Readout System: Adjustment in viewfield and reading on micrometer

• Measuring Accuracy: 0.5 second of arc within a range of 5 minutes of arc.

• Phase Shifting Interferometer (PSI) The Zygo GPI-XP Phase Modulation Interferometer system provides non contact measurement of flat or spherical surfaces, and transmitted wavefront measurement of optical components and assemblies. INTA has many reference spheres to adapt the interferometer to any optical instrument. The high accuracy (< λ/100 P-V) assure the correct measurement of interferometric wavefront for testing End-to-End systems or optical instrument, and it is ideal to perform measurements of alignment verification and optical quality of pre- and post Thermal Vacuum and Vibration testing.

Figure 2. ZYGO interferometer GPI-XP

• On axis Differential Interferometer (ODI)

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The equipment (Agilent 10719A) is basically a very compact interferometer allowing differential measurements between a measurement mirror and a reference mirror. The sub micron resolution (better than 5 nm.), friendly use and long range of measurements (up to 10m.) make this system as ideal to analyze optical alignment in vacuum conditions with complicated geometries.

• Control Measurement Machina

Figure 3. 7-axis FARO Platinum series

The Platinum FaroArm’s .0005" accuracy is used for inspecting, reverse engineer or perform CAD-to-Part-analysis on parts, fixtures and assemblies with great precision. It also features true portability and improved ergonomics. The Platinum FaroArm includes extended-use on-board batteries. The portable cmm platform has a universal 3.5" mounting ring for easy adaptability, while the base offers mounting options that afford "measure-where-you make-it capability. The arm itself is internally counterbalanced for "neutral buoyancy" and fatigue-free usage. In fact, overload sensors prevent users from stressing the arm and help ensure precise measurement. FARo arm has 7 axis. With it's pistol grip handle, the seventh axis models provide greater flexibility when used with custom probes; and expands capabilities with the optional FARO Laser Line Probe. Inverted configurations are also available for mounting upside-down in confined spaces or hard to reach areas. FaroArm Test Methods: 1) Single Point Articulation Performance Test (SPAT): The probe of the FaroArm is placed within a conical socket, and individual points are measured from multiple approach directions. Each individual point measurement is analyzed as a range of deviations about the average value for point location. This test is the most recognized method for determining articulating measurement machine repeatability.

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2) Volumetric Performance: Determined by using traceable length artifacts, which are measured at various locations and orientations throughout the working volume of the FaroArm. This test is the most recognized method for determining articulating measurement machine accuracy.

• Long Distance Microscope. This instrument is used to assemble the Focal Plane unit with the optical system. For this operation is needed to take a reference of the imaginary focal plane and mount the active area just in this plane. This instrument allows working from a working distance between 15 and 45 cm. The catadioptric objective included in the instrument allows getting a resolution better than 2 microns, enough to meet any basically integration requirement.

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1.2 EGSE (Electrical Ground Support Equipment)

TBD by IAA. 1.3 SGSE (Software Ground Support Equipment)

TBD by IAA and IAC.

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Annex 1. Verification of the system requirements during AIV Stage 1 Req. No. Req. Tittle Method AIV Master Schedule task 5.2.7 Polarizing beam splitter T, A 2.1 Optical components 5.2.8 Transmission T, A 2.1 Optical components

5.6.3.2 ROCLIs thermal control T, A 2.2 ROCLI´s

5.2.6 Etalon Filter T, A 2.3 Etalons 5.6.4.2 Etalon thermal control T, A 2.3 Etalons

5.6.2.2 Data acquisition T 2.11 On-board software 5.6.2.3 Data storage T 2.11 On-board software 5.6.2.4 CCD synchronization T 2.11 On-board software 5.7.7.3 Acquisition Synchronism T 2.11 On-board software 5.7.7.4 Cameras Synchronization T 2.11 On-board software 5.8.2.1 Time Base T 2.11 On-board software 5.8.2.2 Telecommand T 2.11 On-board software

5.6.6.2 Optics enclosure thermal control T, A 2.13 Optics Enclosure

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