Factory Automation And Controls


The HiCON Integra motion controller is designed for use with Mach4 CNC software and Digital Drives (stepper/servo motors) using Ethernet conectivity. Integra provides excellent integration with Mach4, proven by thousands of satisfied end-users since 2011. The controller generates a hardware synthesized motion pulse train using state-of-the-art FPGA technology that offers extremely smooth motion profiles compared to low cost controllers in the market.

The HiCON Integra is packed with a comprehensive set of features for your CNC applications, and provides an all-in-one solution for controllers and breakout boards that greatly simplifies system integration and maintainence.

Integra offer superb Open-Loop performance. For even higher precision, you can purchase closed-loop feature and connect Glass scale or rotary encoders (via 7737 boards) to implement a full closed loop system for maximum accuracy in machining. The PID closed loop logic compensates for any deviation 1000 times a second while in motion and positions the stepper motor accurately on the trajectory supplied by Mach4.

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

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

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

Note: The HiCON Motion Controller line is intended for use with Windows 10 and higher. Prior Windows versions are not supported.

Please note some specific differences between the different models:
Part# Single 24V Supply # of Motors # of IO NPN IO Relays # of IO Expansion Encoders Encoder Expansion Closed Loop Stepper 30min Remote Login Support
7868 8 16In 8Out 3(Unique) 32In 16Out 3 11
7866 6 16In 8Out 3(Unique) 32In 16Out 3 11
7854 4 16In 8Out 3(Unique) 32In 16Out 3 11

Product Highlights

Base Features

  • 6 Step and Direction Channels using FPGA 2MHz Pulse Engine
  • 3 Quadrature Encoder Inputs
  • 2 Mhz Max Encoder frequency. Encoder resolution multiplied by 4 thru Hardware.
  • 16 24V digital inputs (8 NPN, 8 PNP)
  • 8 24V digital outputs (4 NPN, 4 PNP)
  • 7 TTL low-voltage inputs
  • Ethernet 100Mb connectivity using TCP/IP interface.
  • Hardware configurable limit and estop inputs for ultra-fast system disarm
  • Modes of Motion: Mach4, Point-to-Point, Linear and Circular interpolation, Jogging, Electronic Gearing, Feedrate Override
  • Industrial-strength Aluminum enclosure

Optional Features

  • Expansion up to 11 Quadrature Encoder Inputs
  • Closed Loop Stepper using PID Control for Glass Scale and Rotary Encoders
  • Optional 2 Channel Analog Inputs, Range 0 - 3.3 Volts, 12-bit Resolution
  • Optional 48 Digital I/O available via Expansion Connectors
  • SDK Libraries available for Software Developers.
  • Optional Standalone Operation by programming the unit with BASIC or C programming language for high-speed I/O processing.
  • Hardware and firmware customization available

CNC Features

  • MPG Control using Electronic Gearing for quick response.
  • Probing.
  • Lathe Threading.
  • Rigid Tapping
  • Backlash compensation.
  • Manual Mode
  • 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.
  • Multiple Spindle control type: 0-10v, Servo/Stepper Motor Spindle (OOB Motor)
  • High Speed 3D machining support.
  • Quick connect 15-pin plug for MPG Handwheel

Customer Testimonials

Simple and Easy Setup

HiCON Integra Setup Diagram

Integra Closed Loop Stepper & Industrial Package

The Integra controller allows you to connect Glass scale or Rotary Encoders to implement a full closed loop system for maximum accuracy in machining. The PID closed loop logic compensates for any deviation while in motion and positions the stepper motors accurately on the trajectory supplied by Mach4. This ensures that all stepper motors are always in sync with the trajectory and that the machine is operating at maximum accuracy.

The closed loop feature also accounts for any missing steps during transmission, and will automatically apply the necessary position correction. 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. Also aditional encoders are accessible with Differential mode. We offer Drive-Interface baords for our AC Servo Motors and Drives, allowing the the connection to servo drives a matter of pluging RJ45 cables.

Get a discount when you purchase the Closed-Loop Package:

  • 7866-CL4: HiCON Integra 7866 with 6 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

For Mach4-Industrial version with discounted pricing, please see the price list below.

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

As Mach4 has become the mainstream CNC software, we have stopped supporting Mach3. Also note that the older 7766 model is obsolete and it is not recomended for new installations. Please select 7866 model instead. If you do need to order older 7766 verison, please see the ordering table at the bottom of this page.


HiCON Basic Setup Video

Mach4 in production run G52 offset with Sub

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]: 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]: Enables 24 additional I/O points on J7 and J8 socket, and also enables Mach4 Sync Outputs (M62/M63). This feature is included with the purchase of 7535 I/O Board. It can also be purchased individually without the 7535 hardware, but please note that working directly with the J7/J8 ports without optical isolation can damage the 3.3V pins.

HiCON-ADC[1]: This software feature enables the use of the 2 analog inputs located on J6.

ArcPro Plasma features[1]: M4ARCPRO software feature allows the use of ArcPro Plasma screen. 77ISO is required to read the plasma analog voltage. For packages and more information visit ARCPRO page.

INTG-CLOOP[1]: This software feature allows Closed-Loop Stepper operation with or without PID control and enables Encoder channels 3-8 on J7/J8. Using the 7737 Board greatly simplifies wiring for Encoder Feedback and Step/Dir channels on J7 and J8.

YSK-ABS[1]: This software feature allows the use of Yaskawa Absolute Encoder feature. Only compatible with Yaskawa Drives with absolute Encoder models. Ask sales for more information .

7737 Board: 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: 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

We are looking for your awesome videos showcasing your machine and our 7866 HiCON controller. Send us videos and get 10% to 20% discount (depends on quality) on your next purchase of any of our motion controller. If you dont plan to purchase, we will refund you as a gift for making the video.

Here are some pointers for creating a good demo video:
  • This is a good example video a previous customer made for us.
  • The video demonstrates a part being created.
  • The video specifically shows our controller wired up and operating in a clean well organized panel.
  • Lots of camera angles and good editing (high quality editing is not 100% necessary, but the video should at least look somewhat professional)
  • Ultimately the amount for the discount (upto 20%) will depend on the quality of the video. A high quality video can receive a high discount, while it may be hard to justify a discount if the video will be difficult to use for marketing.

Price List

Part # Description Price Add to Order

Discount Packages

7866-Mach4 HiCON Integra 7866 & Mach4-Hobby License ($20 Discount) $775 Add to order
Integra-LATHE HiCON Integra 7854, THREADING, Mach4-Hobby License ($50 Discount) $745 Add to order
7866-CL4 HiCON Integra Closed Loop 4-Axis Package $1485 Add to order
7866-CL6 HiCON Integra 7866 Closed Loop 6-Axis Package $1685 Add to order
7868-CL8 HiCON Integra Closed Loop 8-Axis Package $1985 Add to order


7866 HiCON Integra Motion Controller 6-Axis $595 Add to order
7854 HiCON Integra Motion Controller 4-Motors $545 Add to order
7868 HiCON Integra Motion Controller 8-Axis $1000 Add to order
7766 HiCON Integra Controller (Older Model) $995 Add to order

Breakout Boards

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

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 $495 Add to order
HiCON-MACRO HiCON C Programming Feature $475 Add to order
HiCON-EXTIO HiCON Extended I/O Feature (Includes Mach4 Sync Outputs M67, M62) 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 $495 Add to order
YSK-ABS Absolute Encoder Feature for Yaskawa $1000 Add to order
THREADING Lathe Threading Feature Activation $50 Add to order
RIGID_TAP Rigid Tap Feature Activation $275 Add to order


MPG06ED MPG06 Unit w/ DB15M + EStop Button + Differential Encoder $295 Add to order
PW50V24 Power Supply 24V 2.2A 50W $40 Add to order