Wiki source code of 2. Installation and connection

Version 81.4 by Admin on 2026/03/25 16:33

version	line-number	content
31.1	1	(% data-numbered-headings-start="2" style="--numbered-headings-start: 1;font-size: 0px;color: rgba(0, 0, 0, 0.0);margin-bottom: 0px; margin-top: 0px;" %)
	2	= Installation and connection =
30.1	3
57.1	4	== Safety rules ==
	5
61.1	6	To perform the protection functions, the BMS must be able to disconnect the battery from the load and charger. To do this, at least one contactor able to break the load and charge circuits must be connected to the BMS.
57.1	7
59.1	8	Before use, configure the system. Proper operation of the BMS is possible only if it is correctly configured.
57.1	9
62.1	10	(% class="box errormessage" %)
56.2	11	(((
57.1	12	The BMS can be connected to batteries with life-threatening and health-hazardous voltage levels. When working with high-voltage batteries, observe electrical safety regulations, use safety glasses, protective clothing, insulated tools and appliances. To prevent the damage of device avoid electrostatic discharges while working with the battery.
56.2	13	)))
	14
	15	(% class="box errormessage" %)
	16	(((
62.1	17	The system is not designed to operate with batteries whose total voltage exceeds 3000 V.
56.2	18	)))
	19
28.1	20	== Installation procedure ==
27.1	21
78.2	22	The mounting location of the BMS Main 2R device must be protected from mechanical particles (dust, dirt, large objects) and water. The installation location must provide easy access for subsequent connection to the device connectors.
27.1	23
	24	Overall and mounting dimensions are shown in figure below.
	25
81.2	26	[[image:1774349658793-888.0b.STEP.JPG\|\|data-xwiki-image-style-alignment="center" height="522" width="450"]](% title="Click and drag to resize" %)
27.1	27
	28	\|Parameter\|Value
81.2	29	\|Overall dimensions (length × width × height), mm\|120 × 120 × 16
	30	\|Mounting dimensions (length × width), mm\|114 × 114
27.1	31	\|Mounting holes\|M3
	32
30.1	33	== Headers ==
27.1	34
78.2	35	The location and designation of connectors on the BMS Main 2R device are shown below.
27.1	36
	37	(% contenteditable="false" tabindex="-1" %)
	38	(((
81.2	39	[[image:1774455018488-627.png\|\|data-xwiki-image-style-alignment="center"]]
27.1	40	)))
	41
	42	(% class="box warningmessage" %)
	43	(((
	44	Attention!
	45	All headers are shown from the device side!
	46	)))
	47
81.2	48	=== X1 – header for discrete inputs and outputs ===
27.1	49
55.3	50	Receptacle Housing: Hirose ZE05-8DS-HU/R. Terminals: Hirose ZE05-2022SCF
	51
27.1	52	(% class="wikigeneratedid" id="H" %)
81.2	53	[[image:1732198937514-731.png\|\|data-xwiki-image-style-alignment="center" height="85" width="272"]]
27.1	54
	55	\|Pin\|Name\|Description
81.2	56	\|1–8\|GND\|Ground
81.4	57	\|9\|DO_1\|Discrete output 1 (+5V, 20mA)
	58	\|10\|DO_2\|Discrete output 2 (+5V, 20mA)
	59	\|11\|DO_3\|Discrete output 3 (+5V, 20mA)
	60	\|12\|DO_4\|Discrete output 4 (+5V, 20mA)
	61	\|13\|DI_4\|Discrete input 4 “dry contact” (+5V)
81.3	62	\|14\|DI_3\|Power-on signal
	63	\|15\|DI_2\|Power-on signal (battery charge requirement)
	64	\|16\|DI_1\|Power line (9-32V)
27.1	65
	66	Power supply connection diagram:
	67
	68	(% aria-label="1732120054870-496.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732120054870-496.png\|\|data-xwiki-image-style-alignment="center" height="169" width="327"]]
	69
30.1	70	=== X2 – header for contactors ===
27.1	71
55.3	72	Receptacle Housing: Hirose ZE05-12DS-HU/R. Terminals: Hirose ZE05-2022SCF
	73
27.1	74	(% aria-label="1732121695049-411.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121695049-411.png\|\|data-xwiki-image-style-alignment="center" height="87" width="267"]](% title="Click and drag to resize" %)
	75
	76	\|Pin\|Name\|Description
	77	\|1–4, 8–9\|GND\|Ground
	78	\|5\|CONT1_OUT\|Contactor control 1 (plus)
	79	\|6\|CONT2_OUT\|Contactor control 2 (plus)
	80	\|7\|CONT3_OUT\|Contactor control 3 (plus)
	81	\|10\|CONT4_OUT\|Contactor control 4 (plus)
	82	\|11\|CONT5_OUT\|Contactor control 5 (plus)
	83	\|12\|CONT6_OUT\|Contactor control 6 (plus)
	84
	85	Contactor connection diagram:
	86
	87	(% aria-label="1732121755886-234.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121755886-234.png\|\|data-xwiki-image-style-alignment="center" height="82" width="260"]]
	88
30.1	89	=== (% title="Click and drag to resize" %)(%%)X3 – header for discrete inputs and outputs ===
27.1	90
55.3	91	Receptacle Housing: Hirose ZE05-24DS-HU/R. Terminals: Hirose ZE05-2022SCF
	92
27.1	93	(% aria-label="1732121811285-182.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121811285-182.png\|\|data-xwiki-image-style-alignment="center" height="94" width="531"]]
	94
	95	\|Pin\|Name\|Description
	96	\|1–8, 12, 16–17, 21\|DIO_GND\|Ground of input and output signals
36.1	97	\|9\|DIN1_SIGNAL\|Discrete input 1 “dry contact”
	98	\|10\|DIN2_SIGNAL\|Discrete input 2 “dry contact”
	99	\|11\|DIN3_SIGNAL\|Discrete input 3 “dry contact”
	100	\|13\|DIN4_SIGNAL\|Discrete input 4 “dry contact”
	101	\|14\|DIN5_SIGNAL\|Discrete input 5 “dry contact”
	102	\|15\|DIN6_SIGNAL\|Discrete input 6 “dry contact”
27.1	103	\|18\|DIN7_VIN\|Discrete input 7 (signal detection with voltage 9-32V)
	104	\|19\|DIN8_VIN\|Discrete input 8 (signal detection with voltage 9-32V)
	105	\|20\|DOUT1_OD\|Discrete output 1 “open drain” (60 V, 1A)
	106	\|22\|DOUT2_OD\|Discrete output 2 “open drain” (60 V, 1A)
	107	\|23\|DOUT3_OD\|Discrete output 3 “open drain” (60 V, 1A)
	108	\|24\|DOUT4_OD\|Discrete output 4 “open drain” (60 V, 1A)
	109
	110	Connection diagram of a discrete input to a dry contact output:
	111
	112	(% aria-label="1732121887401-555.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121887401-555.png\|\|data-xwiki-image-style-alignment="center" height="63" width="196"]](% title="Click and drag to resize" %)(%%)Connection diagram of a discrete input to an open collector output:
	113
	114	(% aria-label="1732122137116-973.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732122137116-973.png\|\|data-xwiki-image-style-alignment="center" height="100" width="274"]](% title="Click and drag to resize" %)(%%)Connection diagram for a discrete input for detecting a 9-32V signal:
	115
	116	(% aria-label="1732121926812-202.png image widget" data-widget="image" contenteditable="false" role="region" tabindex="-1" %)[[image:1732121926812-202.png\|\|data-xwiki-image-style-alignment="center" height="76" width="242"]](% title="Click and drag to resize" %)(%%)Connection diagram for discrete output:
	117
51.1	118	[[image:1739361269041-663.png\|\|data-xwiki-image-style-alignment="center" height="93" width="275"]]
	119
30.1	120	=== X4 – header for HVIL ===
27.1	121
55.3	122	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	123
30.1	124	[[image:1732122015188-642.png\|\|data-xwiki-image-style-alignment="center" height="64" width="150"]]
27.1	125
	126	\|Pin\|Name\|Description
	127	\|1\|-\|Not used
	128	\|2\|HVIL_OUT\|Output of the current measurement circuit in the current loop (lower potential, measuring shunt output)
	129	\|3\|HVIL_IN\|Input of the current measurement circuit in the current loop (higher potential, measuring shunt input)
	130	\|4\|HVIL_PWR\|Current loop power supply (max 5V, 25mA)
	131
78.2	132	If the BMS Main 2R device generates current in a current loop, the current loop must be connected to the HVIL_PWR and HVIL_IN pins. If BMS Main 2R is a passive current loop meter, then the current loop must be connected to the HVIL_IN and HVIL_OUT pins.
27.1	133
	134	Connection diagram to the current loop:
	135
54.1	136	[[image:1739361367866-742.png\|\|data-xwiki-image-style-alignment="center" height="210" width="281"]]
	137
31.1	138	=== X5 – header for current and temperature sensors ===
27.1	139
55.3	140	Receptacle Housing: Hirose ZE05-16DS-HU/R. Terminals: Hirose ZE05-2022SCF
	141
30.1	142	[[image:1733311958053-469.png\|\|data-xwiki-image-style-alignment="center" height="83" width="349"]]
27.1	143
	144	(% style="width:539px" %)
	145	\|Pin\|Name\|(% style="width:402px" %)Description
	146	\|1\|CS1_5V\|(% style="width:402px" %)Current sensor 1 power line (5 V, max 50 mA)
	147	\|2–6\|GND\|(% style="width:402px" %)Ground
	148	\|7\|CS1_IN1\|(% style="width:402px" %)Current sensor 1 signal line (for a dual-range current sensor, High range output)
	149	\|8\|CS1_REF_IN2\|(% style="width:402px" %)Current sensor 1 reference voltage signal line (for a dual-range current sensor, Low range output)
	150	\|9\|CS2_5V\|(% style="width:402px" %)Current sensor 2 power line (5 V, max 50 mA)
	151	\|10\|CS2_IN1\|(% style="width:402px" %)Current sensor 2 signal line (for a dual-range current sensor, High range output)
	152	\|11\|CS2_REF_IN2\|(% style="width:402px" %)Current sensor 2 reference voltage signal line (for a dual-range current sensor, Low range output)
	153	\|12\|CS3_5V\|(% style="width:402px" %)Current sensor 3 power line (5 V, max 50 mA)
	154	\|13\|CS3_IN1\|(% style="width:402px" %)Current sensor 3 signal line (for a dual-range current sensor, High range output)
	155	\|14\|CS3_REF_IN2\|(% style="width:402px" %)Current sensor 3 reference voltage signal line (for a dual-range current sensor, Low range output)
	156	\|15\|TEMP1\|(% style="width:402px" %)Temperature sensor 1 signal line (NTC-thermistor 100 kOhm)
	157	\|16\|TEMP2\|(% style="width:402px" %)Temperature sensor 2 signal line (NTC-thermistor 100 kOhm)
	158
	159	Current sensor connection diagram (using the example of LEM HASS 100-S):
	160
	161	[[image:1733316158040-285.png\|\|data-xwiki-image-style-alignment="center" height="170" width="412"]]
	162
	163	Current sensor connection diagram (using the example of LEM DHAB S/118):
	164
	165	[[image:1733316170709-142.png\|\|data-xwiki-image-style-alignment="center" height="171" width="413"]]
	166
	167	NTC-thermistor connection diagram:
	168
	169	[[image:1733316189878-329.png\|\|data-xwiki-image-style-alignment="center" height="130" width="260"]]
	170
30.1	171	=== X6 – header for CAN1 and RS-485-1 (external buses) ===
27.1	172
55.3	173	Receptacle Housing: Hirose ZE05-5S-HU/R. Terminals: Hirose ZE05-2022SCF
	174
27.1	175	[[image:1733316218666-814.png\|\|data-xwiki-image-style-alignment="center" height="55" width="162"]]
	176
	177	\|Pin\|Name\|Description
	178	\|1\|CAN1_H\|CAN1 line H for communication with external equipment
	179	\|2\|CAN1_L\|CAN1 line L for communication with external equipment
	180	\|3\|CAN1_RS485_1_GND\|Ground of CAN1 and RS-485-1
	181	\|4\|RS485_1_A\|RS-485-1 line A for communication with external equipment
	182	\|5\|RS485_1_B\|RS-485-1 line B for communication with external equipment
	183
	184	Connection diagram to the CAN1 bus:
	185
	186	[[image:1733316241362-843.png\|\|data-xwiki-image-style-alignment="center" height="153" width="410"]]
	187
	188	Connection diagram to the RS-485-1 bus:
	189
	190	[[image:1733316483336-290.png\|\|data-xwiki-image-style-alignment="center" height="152" width="417"]]
	191
30.1	192	=== X7 – header for CAN2 (internal bus) ===
27.1	193
55.3	194	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	195
27.1	196	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	197
	198	\|Pin\|Name\|Description
38.1	199	\|1\|CAN2_H\|CAN2 line H for communication with other BMS devices
	200	\|2\|CAN2_L\|CAN2 line L for communication with other BMS devices
27.1	201	\|3\|GND\|Ground
	202	\|4\|CAN2_5V\|CAN2 power line (5 V, max 400 mA)
	203
	204	Connection diagram to the CAN2 bus (using the example of connecting BMS Display 1.2):
	205
	206	[[image:1733316563149-458.png\|\|data-xwiki-image-style-alignment="center" height="158" width="392"]]
	207
30.1	208	=== X8 – header for CAN3 ===
27.1	209
55.3	210	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	211
27.1	212	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	213
	214	\|Pin\|Name\|Description
38.1	215	\|1\|CAN3_H\|CAN3 line H
	216	\|2\|CAN3_L\|CAN3 line L
27.1	217	\|3\|GND\|Ground
	218	\|4\|CAN3_5V\|CAN3 power line (5 V, max 400 mA)
	219
	220	(% class="box infomessage" %)
	221	(((
38.1	222	Note:
	223	CAN3 operates differently depending on used firmware:
27.1	224
38.1	225	* BMS Main 3: CAN3 bus is reserved;
39.1	226	* BMS Main 3X: CAN3 bus is used to connect with BMS Main 3 inside parallel strings. Diagram for connecting battery modules to the CAN3 bus:
38.1	227
	228	[[image:1733316622613-181.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="417"]]
	229	)))
27.1	230
30.1	231	=== X9 – header for BMS Logic (RS-485-2) ===
27.1	232
55.3	233	Receptacle Housing: Hirose ZE05-4S-HU/R. Terminals: Hirose ZE05-2022SCF
	234
27.1	235	[[image:1733316517741-698.png\|\|data-xwiki-image-style-alignment="center" height="59" width="144"]]
	236
	237	\|Pin\|Name\|Description
	238	\|1\|LOGIC_B\|RS-485 line B for communication with BMS Logic
	239	\|2\|LOGIC_A\|RS-485 line A for communication with BMS Logic
	240	\|3\|GND\|Ground
	241	\|4\|LOGIC_5V\|BMS Logic power line (+5V, max 400mA)
	242
40.1	243	(% class="box infomessage" %)
	244	(((
	245	Note:
	246	RS-485-2 operates differently depending on used firmware:
27.1	247
40.1	248	* BMS Main 3X: RS-485-2 bus is reserved;
	249	* BMS Main 3: RS-485-2 bus is used to connect with BMS Logics in a battery pack. Connection diagram for BMS Logic devices:
27.1	250
40.1	251	[[image:1733316674363-604.png\|\|data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="163" width="400"]]
	252	)))
	253
30.1	254	=== X10 – miniUSB connector ===
27.1	255
78.2	256	The miniUSB connector is used to configure the parameters of the BMS Main 2R device.
27.1	257
30.1	258	=== X11 – header for high-voltage bus before contactors (plus) ===
27.1	259
55.3	260	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	261
27.1	262	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	263
	264	\|Pin\|Name\|Description
	265	\|1\|IN1+\|Plus of the high-voltage bus (before contactors)
	266	\|2\|IN1+\|Plus of the high-voltage bus (before contactors)
	267
	268	(% class="box warningmessage" %)
	269	(((
	270	The connected voltage must not exceed 1000V.
	271	)))
	272
30.1	273	=== X12 – header for high-voltage bus before contactors (minus) ===
27.1	274
55.3	275	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	276
27.1	277	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	278
	279	\|Pin\|Name\|Description
	280	\|1\|IN1-\|Minus of the high-voltage bus (before contactors)
	281	\|2\|IN1-\|Minus of the high-voltage bus (before contactors)
	282
	283	(% class="box warningmessage" %)
	284	(((
	285	The connected voltage must not exceed 1000V.
	286	)))
	287
30.1	288	=== X13 – header for high-voltage bus after contactors (plus) ===
27.1	289
55.3	290	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	291
27.1	292	[[image:1733316780753-798.png\|\|data-xwiki-image-style-alignment="center" height="60" width="91"]]
	293
	294	\|Pin\|Name\|Description
	295	\|1\|IN2+\|Plus of the high-voltage bus (after contactors)
	296	\|2\|IN2+\|Plus of the high-voltage bus (after contactors)
	297
	298	(% class="box warningmessage" %)
	299	(((
	300	The connected voltage must not exceed 1000V.
	301	)))
	302
30.1	303	=== X14 – header for high-voltage bus after contactors (minus) ===
27.1	304
55.3	305	Receptacle Housing: Molex 436450200. Terminals: Molex 43030
	306
27.1	307	[[image:1733316843397-336.png\|\|data-xwiki-image-style-alignment="center" height="53" width="79"]]
	308
	309	\|Pin\|Name\|Description
	310	\|1\|IN2-\|Minus of the high-voltage bus (after contactors)
	311	\|2\|IN2-\|Minus of the high-voltage bus (after contactors)
	312
	313	(% class="box warningmessage" %)
	314	(((
	315	The connected voltage must not exceed 1000V.
	316	)))
	317
30.1	318	=== J1 – jumper for switching RS-485-1 bus terminal resistor ===
27.1	319
	320	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]
	321
	322	To connect a terminal resistor between the RS485_1_A and RS485_1_B lines, install a jumper. The jumper is installed according to the table:
	323
	324	\|Pin\|Name\|Description
	325	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the RS-485-1 bus is connected
	326	\|2-3\|-\|The 120 Ohm terminal resistor of the RS-485-1 bus is disconnected
	327
30.1	328	=== J2 – jumper for switching CAN1 bus terminal resistor ===
27.1	329
	330
	331	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]To connect a terminal resistor between the CAN1_H and CAN1_L lines, install a jumper. The jumper is installed according to the table:
	332
	333	\|Pin\|Name\|Description
	334	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN1 bus is connected
	335	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN1 bus is disconnected
	336
30.1	337	=== J3 – jumper for switching CAN2 bus terminal resistor ===
27.1	338
	339
	340	[[image:1733316982359-759.png\|\|data-xwiki-image-style-alignment="center" height="77" width="148"]]To connect a terminal resistor between the CAN2_H and CAN2_L lines, install a jumper. The jumper is installed according to the table:
	341
	342	\|Pin\|Name\|Description
	343	\|1-2\|120 Ohm\|The 120 Ohm terminal resistor of the CAN2 bus is connected
	344	\|2-3\|-\|The 120 Ohm terminal resistor of the CAN2 bus is disconnected
	345
30.1	346	=== J5, J6 – jumpers for emergency opening of contactors when removing discrete input signals DIN7, DIN8 ===
27.1	347
78.2	348	The BMS Main 2R device implements a circuit for hardware opening of power contactors when the discrete input signal DIN7 and/or DIN8 (voltage level 9-32V) is removed. To enable this function, jumper J5 and/or J6 must be installed.
27.1	349
30.1	350	== Indicators ==
27.1	351
30.1	352	=== DS1 – LED indicating device power ===
27.1	353
	354	\|State\|Description
	355	\|Lights up green\|Device power (+5V) is present
	356	\|Doesn’t light up\|No device power
	357
30.1	358	=== DS2 – LED indicating device work ===
27.1	359
	360	\|State\|Description
	361	\|Blinking green\|Executing the battery management program
	362	\|No blinking\|Program execution error
	363
54.2	364	=== DS3 – LED indicating interaction with child devices ===
27.1	365
54.2	366	(% style="width:447px" %)
	367	\|State\|(% style="width:166px" %)Description (Main 3)\|(% style="width:168px" %)Description (Main 3X)
	368	\|Blinking yellow\|(% style="width:166px" %)The device interacts with BMS Logic devices\|(% style="width:168px" %)The device interacts with BMS Main 3 devices
	369	\|No blinking\|(% style="width:166px" %)-\|(% style="width:168px" %)-
27.1	370
54.2	371	=== DS4 – LED indicating loss of connection with child devices ===
27.1	372
54.4	373	(% style="width:601px" %)
	374	\|State\|(% style="width:220px" %)Description (Main 3)\|(% style="width:218px" %)Description (Main 3X)
	375	\|Blinking/lights up red\|(% style="width:220px" %)Communication with one or more BMS Logic devices is lost\|(% style="width:218px" %)Communication with one or more BMS Main 3 devices is lost
	376	\|No blinking\|(% style="width:220px" %)Communication with BMS Logic devices is stable\|(% style="width:218px" %)Communication with BMS Main 3 devices is stable
27.1	377
30.1	378	=== DS5-DS10 – LEDs indicating contactor switches 1-6 ===
27.1	379
	380	\|State\|Description
	381	\|Lights up green\|The switch supplies voltage to the contactor winding
	382	\|Doesn’t light up\|The switch doesn’t supply voltage to the contactor winding
	383
30.1	384	=== DS11 – LED indicating the presence of power supply for contactors ===
27.1	385
	386	\|State\|Description
	387	\|Lights up green\|Power supply for contactor switches (9-32V) is present
	388	\|Doesn’t light up\|Power supply for contactor switches (9-32V) is not present
	389
30.1	390	== Connection procedure ==
27.1	391
	392	All operations to connect the device must be carried out with the supply voltage removed.
	393
	394	* Connect the power contactors to header X2.
	395	* Connect one or more current sensors, as well as external temperature sensors (if necessary) to header X5.
	396	* Connect BMS Logic devices to header X9.
	397	* Connect digital inputs and outputs (if necessary) to header X3.
	398	* Connect the high voltage bus (if necessary) to headers X11-X14.
	399	* Connect the high-voltage network integrity circuit (if necessary) to header X4.
	400	* Connect external devices (if necessary) to header X6.
	401	* Connect other devices (BMS Indication, BMS Display, if necessary) to header X7.
78.2	402	* If the BMS Main 2R is the last device on the RS-485-1, CAN1, or CAN2 bus, install jumpers J1-J3.
27.1	403	* Connect an external power supply to header X1. The device will start when there is a 9-32V power supply and one of the KEYRUN or CHARGE_ON signals with a voltage of more than 8.5V is supplied.

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