Factory Automation And Controls


Package Discount available for additional purchase of Motors and Drives with this product. Please Contact us to speak with a sales rep.

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.

Related Links

Integra 7866 User Guide

Installation Manuals

Downloads & Mach4 Plugin

Breakout Boards

HiCON Mach Support Forum

SDK/Libraries

Price List

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.,

  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.

Product Highlights

Controller Features

  • 6 Step and Direction Channels. Up to 2MHz Step Frequencies
  • 3 Quadrature Encoder Inputs (Expandable to 9).
  • 4 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 (MPG dedicated)
  • Optional 2 Channel Analog Inputs, Range 0 - 3.3 Volts, 12-bit Resolution
  • Optional 48 Digital I/O available via Expansion Connectors
  • 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
  • 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.
  • Industrial-strength Aluminum enclosure
  • 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.
  • Spindle Orientation and Tool Change Support
  • Multiple Spindle control type: 0-10v, Servo Spindle, GCode Spindle (Allows easy integration of Tool Changer).
  • High Speed 3D machining support.
  • Quick connect 15-pin plug for MPG Handwheel
  • Basic and C Internal programming for fast I/O logic and Tool-Changer Applications

    • Customer Testimonials

    Simple and Easy Setup

    HiCON Integra Setup Diagram


    Integra Closed Loop/Industrial Package

    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

    Integra Documentation

    Integra 7866 User Manual

    Integra 7766 User Manual

    Mach3 Integration Manual

    Mach4 Integration Manual

    VSI Device Manager Manual

    HiCON Basic User Manual

    VSI C-Macro User Manual

    Integra Real-World I/O Examples

    VSI Custom Mach4 Registers Manual

    7737 Wiring

    Closed loop PID configuration

    Rigid Tapping User Guide

    7866 Dimensions

    Integra Plugins and Software

    Integra Mach4 Plugin and Firmware

    VSI Device Manager

    VSI Macro Loader

    Example HiCON Basic Programs

    Mach4 Integra Lathe Profile (Sample)

    Mach4 Integra Mill Profile (Sample)

    Mach3 Files for 7766 (Not Supported)


    Media

    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][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
    Integra-LATHE HiCON Integra 7854, THREADING, Mach4-Hobby License ($50 Discount) $695 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
    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
    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 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
    MPG06ED MPG06 Unit w/ DB15M + EStop Button + Differential Encoder $295 Add to order
    PW50V24 Power Supply 24V 2.2A 50W $40 Add to order
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