Factory Automation And Controls


The HiCON Integra is a motion controller designed for use with Mach4 CNC software and Digital Drives (stepper/servo motors) using Ethernet communications. The HiCON Integra provides excellent integration with Mach4, proven by hundreds 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.

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. Prior Windows versions are unsupported.

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 SDK Motion API 30min Team Viewer Support
7866 6 16In 8Out 3(Unique) 32In 16Out 3 8
7854 4 16In 8Out 3(Unique) 0 0 3 8
7766(Old) Needs additional 5V 6 16In 8Out 5(Shared) 32In 16Out 3 6

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


    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.

    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][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.

    YSK-ABS[1][2]: 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[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.

    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) $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


    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) $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 (Includes Mach4 Sync Outputs M67, M62) Purchase of 7535 I/O board includes this feature! $275 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
    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