stepconf error. help

Stepconf encountered an error. The following information may be useful in troubleshooting:

Traceback (most recent call last):
File "/usr/bin/stepconf", line 1915, in update_axis_params
halrun.flush()
IOError: [Errno 32] Broken pipe

If this error happens consistently then run stepconf from a terminal.
In the terminal it will show the underlying HAL error.
What version of EMC are you using?
You must have tried using motor testing / tuning ?

i run stepconf wizard from teminal and after that when i open emc2 i get this error:


Print file information:
RUN_IN_PLACE=no
EMC2_DIR=
EMC2_BIN_DIR=/usr/bin
EMC2_TCL_DIR=/usr/share/emc/tcl
EMC2_SCRIPT_DIR=
EMC2_RTLIB_DIR=/usr/realtime-2.6.32-122-rtai/modules/emc2
EMC2_CONFIG_DIR=
EMC2_LANG_DIR=/usr/share/emc/tcl/msgs
INIVAR=inivar
HALCMD=halcmd
EMC2_EMCSH=/usr/bin/wish8.5
EMC2 - 2.4.6
Machine configuration directory is '/home/cnc/emc2/configs/ViperaCNC'
Machine configuration file is 'ViperaCNC.ini'
INIFILE=/home/cnc/emc2/configs/ViperaCNC/ViperaCNC.ini
PARAMETER_FILE=emc.var
EMCMOT=motmod
EMCIO=io
TASK=milltask
HALUI=
DISPLAY=axis
NML_FILE=
Starting EMC2...
Starting EMC2 server program: emcsvr
Loading Real Time OS, RTAPI, and HAL_LIB modules
Realtime system did not load
Shutting down and cleaning up EMC2...
Killing task emcsvr, PID=2035
Removing HAL_LIB, RTAPI, and Real Time OS modules
Removing NML shared memory segments
Cleanup done

Debug file information:
insmod: error inserting '/usr/realtime-2.6.32-122-rtai/modules/rtai_hal.ko': -1 File exists
2035
PID TTY STAT TIME COMMAND
Stopping realtime threads
Unloading hal components

Kernel message information:
[ 505.079644] I-pipe: Domain RTAI registered.
[ 505.079655] RTAI[hal]: <3.8.1> mounted over IPIPE-NOTHREADS 2.6-03.
[ 505.079659] RTAI[hal]: compiled with gcc version 4.4.3 (Ubuntu 4.4.3-4ubuntu5) .
[ 505.079667] RTAI[hal]: mounted (IPIPE-NOTHREADS, IMMEDIATE (INTERNAL IRQs DISPATCHED), ISOL_CPUS_MASK: 0).
[ 505.079671] PIPELINE layers:
[ 505.079675] e0601e20 9ac15d93 RTAI 200
[ 505.079678] c085cb20 0 Linux 100
[ 505.143135] RTAI[malloc]: global heap size = 2097152 bytes, <BSD>.
[ 505.143400] RTAI[sched]: IMMEDIATE, MP, USER/KERNEL SPACE: <with RTAI OWN KTASKs>, kstacks pool size = 524288 bytes.
[ 505.143408] RTAI[sched]: hard timer type/freq = APIC/6244649(Hz); default timing: periodic; linear timed lists.
[ 505.143413] RTAI[sched]: Linux timer freq = 250 (Hz), TimeBase freq = 1398690000 hz.
[ 505.143417] RTAI[sched]: timer setup = 999 ns, resched latency = 2944 ns.
[ 505.143605] RTAI[usi]: enabled.
[ 505.261256] RTAI[math]: loaded.
[ 505.350842] config string '0x378'
[ 540.950441] RTAI[math]: unloaded.
[ 541.019888] SCHED releases registered named ALIEN RTGLBH
[ 541.033192] RTAI[malloc]: unloaded.
[ 541.132017] RTAI[sched]: unloaded (forced hard/soft/hard transitions: traps 0, syscalls 0).
[ 541.137530] I-pipe: Domain RTAI unregistered.
[ 541.137544] RTAI[hal]: unmounted.

now i've got the error

/usr/bin/stepconf:24: DeprecationWarning: the md5 module is deprecated; use hashlib instead
import md5
/usr/bin/stepconf:1156: Warning: g_path_get_dirname: assertion `file_name != NULL' failed
self.xml = gtk.glade.xml_new_from_buffer(doc, len(doc), domain="axis")
/usr/bin/stepconf:1156: GtkWarning: gdk_pixbuf_new_from_file: assertion `filename != NULL' failed
self.xml = gtk.glade.xml_new_from_buffer(doc, len(doc), domain="axis")
/usr/bin/stepconf:1156: Warning: g_object_unref: assertion `G_IS_OBJECT (object)' failed
self.xml = gtk.glade.xml_new_from_buffer(doc, len(doc), domain="axis")
/usr/bin/stepconf:1156: GtkWarning: GtkSpinButton: setting an adjustment with non-zero page size is deprecated
self.xml = gtk.glade.xml_new_from_buffer(doc, len(doc), domain="axis")
/usr/bin/stepconf:2115: GtkWarning: GtkSpinButton: setting an adjustment with non-zero page size is deprecated
widgets.testvel.set_range(0, maxvel)
/usr/bin/stepconf:2116: GtkWarning: GtkSpinButton: setting an adjustment with non-zero page size is deprecated
widgets.testacc.set_range(1, 100000)
/usr/bin/stepconf:2117: GtkWarning: GtkSpinButton: setting an adjustment with non-zero page size is deprecated
widgets.testamplitude.set_range(0, 1000)
Realtime already running. Use 'halrun -U' to stop existing realtime session.

With stepconf HAL errors, halrun -U works almost every time.
after that command run stepconf again from a terminal and if it errors note the error message.

It seems as if you realtime system isn't loading properly.
Did you just get some Ubuntu updates recently?
it could be that the realtime kernel isn't automatically loading anymore.