Factory Automation And Controls
HiCON Integra - 4,6 & 8 Motors Step/Direction Ethernet Motion Controller
Now Shipping the new 7866 version. If you need to order the older 7766 verison, please see the ordering table at the bottom of this page.
HiCON Integra motion controller works Mach4 software and Digital Drives (stepper or servo motors) using Ethernet communications. HiCON Integra 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 profiles compared to the low cost controllers in the market. HiCON Integra is packed with comprehensive set of features for your CNC application and provides an all-in-one solution of controller and breakout board that greatly simplifies system integration and maintainence.
We have launched 7866 and 7854 Motion controllers. Please note some specific differences between 7866, 7854, 7766 units
| Part# | Single 24V Supply | Requires 5V Supply | # of Motors | # of IO | Relays | # of IO Expansion | Encoders | Encoder Expansion | NPN IO | SDK Motion API | 30min Team Viewer Support | ||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 7866 | ✔ | ✖ | 6 | 16In | 8Out | 3 | 32In | 16Out | 3 | 8 | ✔ | ✔ | ✔ |
| 7854 | ✔ | ✖ | 4 | 16In | 8Out | 3 | 0 | 0 | 0 | 0 | ✔ | ✖ | ✖ |
| 7766 | ✖ | ✔ | 6 | 16In | 8Out | 5 | 32In | 16Out | 3 | 6 | ✖ | ✔ | ✔ |
We develop plugin Mach4 plugin software, working closely with Mach Software team. Our Mach4 plugins are the top rated and most comprehensive plugins available.
We have launched 7866 and 7854 Motion controllers. Please note some specific differences between 7766 and 7866 units
| Characteristics | 7866 (New Black Card) | 7766 (Old Blue Card) | ||
|---|---|---|---|---|
| 5V Power Supply | Not required. | No Need for additional 5V power Supply | Required. | Always apply 5V first and then 24V |
| # of Relays | 3 | Isolated Relay Contacts. | 5 | Shared Relay Contacts |
| Type of I/O | Both NPN & PNP | Inputs: 8 PNP(J14) 8 NPN(J13). Outputs: 4PNP 4NPN (J15) | PNP only | Inputs: 16 PNP (J13,J14). Outputs: 8 PNP (J15) |
| Development phase | Stable and Actively Supported | Purchase here | Frozen | Not Recommended For new Design |
| Production Status | In Production | In Production | (Requires MOQ) | |
The Integra controller can be used in a variety of applications, e.g.,
- CNC Routers
- Plasma / Oxy Fuel Tables
- Milling / Lathe CNC Machines
- PC Based or Standalone Motion and I/O Controller
- Storage and Retrieval Systems
- And many other apps....
Also check out the new ARCPRO Plasma Controls for torch height control functionality with this controller.
Product Highlights
Controller Features
CNC Features
Customer Testimonials
Simple and Easy Setup
HiCON Integra Setup Diagram
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.
With 7737 board, you can use RJ45 cables between the controller and the motor drivers. We offer Drive-Interface baords for the AC Servo Motors and Drives we offer, thus making the installation almost plug-and-play
Get a discount when you purchase the Closed-Loop Package:
- 7866-CL4: HiCON Integra 7866 with 4 Motor Enabled, One 7737 Step/Dir Encoder Board, Integra Closed Loop Activation, Extended I/O Activation, Mach4-Hobby License
- 7866-CL6: HiCON Integra 7866 with 6 Motor Enabled, Two 7737 Step/Dir Encoder Boards, Integra Closed Loop Activation, Extended I/O Activation Mach4-Hobby License
- 7868-CL8: HiCON Integra 7868 with 8 Motor Enabled, Two 7737 Step/Dir Encoder Boards, Integra Closed Loop Activation, Extended I/O Activation Mach4-Hobby License
We also offer these packages with Mach4-Industrial version with discounted pricing.
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 software releases, please refer to the download section below
Note: As Mach4 has become the mainstream CNC software, Mach3 Plugin development is now frozen. Mach3 will only work with 7766 and won't work with the new Integra 7866. The old Mach3 files are still available in case you like to downgrade the software on the 7766 controller. We provide tech-support for Mach4 based installations only
Optional Components for HiCON Integra System
Most CNC applications will only require the Integra base controller. However, advanced applications can benefit from these addons:
HiCON-MACRO[1][2]: This software feature allows the user to write custom programs (in C and BASIC languages)which can be downloaded to the controller for fast execution. Advantages of HiCON-Macro Include:
- Real-time program execution
- Ultra-fast I/O manipulation (eg. Tool Changer)
- Extends Mach 3/4 Functionality
- Run as standalone unit - No PC Required during operation
HiCON-EXTIO[1][2]: This software feature extends the number of available I/O by enabling ports J7 and J8. Useful if the built-in inputs and outputs are not sufficient. This feature also enables Mach4 Sync Outputs (M62/M63).
HiCON-ADC[1]: This software feature allows the use of the 2 analog inputs located on J6.
INTG-CLOOP[1][2]: This software feature allows Closed-Loop operation and enables Step/Dir channels 0-3 and Encoder channels 3-6 on J8, as well as Step/Dir channels 4-5 and Encoder channels 7-8 on J7. Using the 7737 Board greatly simplifies wiring for Encoder Feedback and Step/Dir channels on J7 and J8.
7737 Board[2]: The pn7737 Differential Step/Direction and Encoder Board allows access to the Step/Direction and Encoder channels on J7 and J8 plugs, and allows a simple plug-and-play setup using standard RJ45/Ethernet cables. When used with Drive Interface Board (EPx-DIB) for Maxsine AC Servo Drives, this board provides almost plug and play installation. In order to use encoders for Axis Feedback purpose, 'Closed Loop Activaion' must be purchased.
7535 Board[2]: The I/O Termination board (7535P or 7535N) provides 24 Volts optically isolated digital I/O. Each board has 16 input terminals and 8 output terminals. All I/O terminals are clearly marked for quick and easy installation. Upto two 7535 (N or P) boards can be plugged into HiCON Integra, providing additional 32 Inputs and 16 outputs (24Volts 1Amp).
[1] - These items may be purchased any time before or after shipping as they are software feature enablers
[2] - Not Applicable for Integra Hobby model.
Price List
| Part # | Description | Price | Add to Order |
|---|---|---|---|
Discount Packages |
|||
| 7866-Mach4 | HiCON Integra 7866 & Mach4-Hobby License ($20 Discount) | $775 | Add to order |
| 7866-CL4 | HiCON Integra Closed Loop 4-Axis Package | $1535 | Add to order |
| 7866-CL6 | HiCON Integra 7866 Closed Loop 6-Axis Package | $1780 | Add to order |
| 7868-CL8 | HiCON Integra Closed Loop 8-Axis Package | $2185 | Add to order |
Controllers |
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| 7866 | HiCON Integra Motion Controller 6-Axis | $595 | Add to order |
| 7854 | HiCON Integra Motion Controller 4-Motors | $495 | Add to order |
| 7868 | HiCON Integra Motion Controller 8-Axis | $1000 | Add to order |
| 7766 | HiCON Integra Controller (Older Model) | $695 | Add to order |
Breakout Boards |
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| 7535P | 16in/8Out OptoIsolated PNP Sourcing Type I/O Board | $275 | Add to order |
| 7535N | 16in/8Out OptoIsolated NPN Sink Type I/O Board | $275 | Add to order |
| 7737 | Differential Step/Dir and Encoder Board | $295 | Add to order |
Software and Add-ons |
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| MACH4-INDUSTRIAL | Mach4-Industrial Software License | $1295 | Add to order |
| Mach4-Hobby | Mach4-Hobby Software License | $200 | Add to order |
| Mach3 | Mach3 Software License | $175 | Add to order |
| MOTION_API | Motion and I/O Control API from Windows PC | $350 | Add to order |
| HiCON-MACRO | HiCON Basic & C Programming Feature | $475 | Add to order |
| HiCON-EXTIO | HiCON Extended I/O Feature (Enable I/O Ports 12 & 13, and Mach4 Sync Outputs) Purchase of 7535 I/O board includes this feature! | $200 | Add to order |
| HiCON-ADC | HiCON Analog Input Feature Activation | $200 | Add to order |
| INTG-CLOOP | HiCON Integra Closed Loop Activation | $595 | Add to order |
| THREADING | Lathe Threading Feature Activation | $50 | Add to order |
| RIGID_TAP | Rigid Tap Feature Activation | $275 | Add to order |
Accessories |
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| MPG06ED | MPG06 Unit w/ DB15M + EStop Button + Differential Encoder | $295 | Add to order |
| PW50V24 | Power Supply 24V 2.2A 50W | $40 | Add to order |