The exact error message you're getting would be helpful.  I'm guessing
it's actually this message, with %s replaced by the name of the signal:
    "HAL: ERROR: insufficient memory for signal '%s'\n"
is that correct?

If so, you're probably also bumping the limit on the hal shared memory
segment.  You can see the amount available at any time with a 'status'
command.  Insert it just above the failing line, and then have a look at
the output.

Here with nothing loaded, I get:

$ halcmd status
HAL locking status:
  current lock value 0 (00)
  HAL_LOCK_NONE - nothing is locked
HAL memory status
  used/total shared memory:   264/262000
  active/recycled components: 1/0
  active/recycled pins:       0/0
  active/recycled parameters: 0/0
  active/recycled aliases:    0/0
  active/recycled signals:    0/0
  active/recycled functions:  0/0
  active/recycled threads:    0/0

If you've reached the limit, then you can increase it by modifying the
#define HAL_SIZE directive in hal_priv.h, then rebuilding, like so:

diff --git a/src/hal/hal_priv.h b/src/hal/hal_priv.h
index 1ef1f74..b0550d0 100644
--- a/src/hal/hal_priv.h
+++ b/src/hal/hal_priv.h
@@ -325,7 +325,7 @@ typedef struct {
 
 #define HAL_KEY   0x48414C32   /* key used to open HAL shared memory */
 #define HAL_VER   0x0000000C   /* version code */
-#define HAL_SIZE  262000
+#define HAL_SIZE  1048576
 
 /* These pointers are set by hal_init() to point to the shmem block
    and to the master data structure. All access should use these


Jeff

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