HiCON Mini - 4-Axis Step/Direction Ethernet Motion Controller (pn 77E4)


HiCON Mini motion controller works with Mach4 software and Digital Drives (stepper or servo motors) using Ethernet communications. HiCON Mini provides excellent integration with Mach4 CNC software, proven by hundreds of end-users since 2011. The controller generates hardware synthesized motion pulse train using state-of-the-art FPGA devices that offers extremely smooth motion profies compared to the low cost controllers in the market. HiCON Mini is packed with a comprehensive set of features for your CNC application and provides an all-in-one solution of controller that greatly simplifies system integration and maintainence.

We have developed plugins for Mach4 software, working closely with Mach Software development team. Our Mach4 plugins are the top rated and most comprehensive plugins available.

The HiCON Mini controller can be used in a variety of applications, e.g.,

  1. CNC Routers
  2. PC Based or Standalone Motion and I/O Controller
  3. Storage and Retrieval Systems
  4. Milling / Lathe CNC Machines
  5. CNC Plasma Machines
  6. And many other apps....

Also check out the new ARCPRO Plasma Package for torch height control functionality with this controller.

Product Highlights

Controller Features

  • 4 Step and Direction Channels. Up to 2MHz Step Frequencies
  • 6 Mhz Max Encoder frequency. Encoder resolution multiplied by 4 thru Hardware.
  • Optional 4 Quadrature Encoder Inputs
  • Optional 1 isolated analog input for Plasma applications, range 0-10 volts, 10-bit resolution
  • 6 digital NPN inputs (5 to 24v)
  • 4 digital NPN outputs (5 to 24v)
  • Ethernet 100Mb connectivity using TCP/IP interface.
  • Hardware configurable limit and estop inputs for ultra-fast system disarm
  • Modes of Motion: Point-to-Point, Linear and Circular interpolation, Jogging, Electronic Gearing, Feedrate Override
  • Optional software Libraries available for custom PC-based and Standalone applications
  • Hardware and firmware customization available

CNC Features

  • Probing.
  • Lathe Threading.
  • Rigid Tapping
  • Backlash compensation.
  • Manual CNC Mode (requires some scripting on Mach side)
  • Homing Using Home Sensor and/or Index Pulse.
  • Rotary Axis Homing with Index pulse.
  • Use One Home Sensor Input for all axis, or separate Home Sensors for each axis.
  • Use Limit switches as homing sensors.
  • Feedrate Override above 100%.
  • Instant FeedHold
  • Slave Axis Support.
  • PID Tuning Graph.
  • Tool Changer operation with Mach4 macros
  • High-Speed 3D machining support.

HiCON Mini Closed Loop Option

This setup provides a great solution for applications that require accuracy and reliability. The closed loop feature accounts for any missing steps during transmission, and will automatically apply the necessary position correction at the start of the next move. This prevents following errors from accumulating. In addition, the DROs on Mach4 will show the actual machine position instead of just a step counter. Closed loop option also allows you to use the mill in manual mode where you manipulate the axis manually while seeing the actual positions in the DROs.

Mach4 CNC Software

Mach4 is an excellent PC-based software solution for CNC. When paired with a HiCON motion controller, it creates a state of the art CNC solution for machine-shops as well as industrial applications. Mach4 plus HiCON greatly simplifies retrofitting and increases operation reliability. For the latest release of the Mach4 HiCON Plugin, please refer to the download section below.

Note: As Mach4 has become the mainstream CNC software, we have stopped supporting Mach3.


HiCON Basic Setup Video

Price List


77E4 $225
HiCON Mini 4-Axis Motion Controller Add to order
77E4AN $325
HiCON Mini Motion Controller w/ Built-In Plasma Tip Voltage Sensor Add to order
77E4PL $595
ArcPro Plasma Combo ($150 discount) Includes: 77E4 Motion Controller, ArcPro logic and screen, Plasma Tip Voltage Sensor, Mach4 Hobby, 24V Power Supply Add to order

Software and Add-ons

HiCON Integra Closed Loop Activation Add to order
Mach4-Industrial Software License Add to order
Mach4-Hobby $200
Mach4-Hobby Software License Add to order


PW50V24 $40
Power Supply 24V 2.2A 50W Add to order