I've set up a few 4 axis machines using W axis. There are some things you have 
to change in your ini file.
In your TRAJ section of your ini.  Change the number of axis to 9, and then add 
blank [AXIS_N] place holders for the unused axis 3-7 and change the W to 
[AXIS_8].  Then you'll also need to change all the appropriate references in 
the hal file to reflect these changes.
see below.

[TRAJ]

AXES =                  9
# COORDINATES =         X Y Z R P W
COORDINATES =           X Y Z W
HOME =                  0 0 0 0
LINEAR_UNITS =          inch
ANGULAR_UNITS =         degree
CYCLE_TIME =            0.010
DEFAULT_VELOCITY =      1.6
MAX_VELOCITY =          5.0
DEFAULT_ACCELERATION =  15.0
MAX_ACCELERATION =      20.0
PROBE_INDEX =           0
PROBE_POLARITY =        1

# Axes sections ---------------------------------------------------------------

# First axis X
 #3653.934521324
[AXIS_0]

TYPE =                          LINEAR
HOME =                          0.000
MAX_VELOCITY =                  3.33333
MAX_ACCELERATION =              30.0
PID_MAX_VEL =             4.0
BACKLASH = 0.000
#INPUT_SCALE =                   3552.5328
#OUTPUT_SCALE = 3552.5328
#67094.656415937
INPUT_SCALE =                   -16773.66
OUTPUT_SCALE =                  -16773.66
MIN_LIMIT =                     -2.0
MAX_LIMIT =                     48.0
FERROR = 1.5
MIN_FERROR = 0.05
HOME_OFFSET =                    0.0
HOME_SEARCH_VEL =                0.0
HOME_LATCH_VEL =                 0.0
HOME_USE_INDEX =                 NO
HOME_IGNORE_LIMITS =             NO
DEADBAND =                         0.000089
P =                              10
I =                              0
D =                                0.1
BIAS =                             0
FF0 =                              0
FF1 =                              1.2
FF2 =                              0.002


# Second axis Y
[AXIS_1]

TYPE =                          LINEAR
HOME =                          0.000
MAX_VELOCITY =                  3.3333
MAX_ACCELERATION =              16.0
PID_MAX_VEL =              4.0
BACKLASH = 0.000
#INPUT_SCALE =                   -8842.815
#OUTPUT_SCALE = -8842.81
INPUT_SCALE =                   -7942.321
OUTPUT_SCALE = -7942.321
MIN_LIMIT =                     -2.0
MAX_LIMIT =                    96.0
FERROR = 1.0
MIN_FERROR = 0.05
HOME_OFFSET =                    0.0
HOME_SEARCH_VEL =                0.0
HOME_LATCH_VEL =                 0.0
HOME_USE_INDEX =                 NO
HOME_IGNORE_LIMITS =             NO
DEADBAND =                         0.000188869
P =                              10
I =                              0
D =                                0.1
BIAS =                             0
FF0 =                              0
FF1 =                              1.2
FF2 =                              0.002

# Third axis Z
[AXIS_2]

TYPE =                          LINEAR
HOME =                          0.0
MAX_VELOCITY =                  2.1
MAX_ACCELERATION =              24.0
PID_MAX_VEL =              2.2
BACKLASH = 0.000
#INPUT_SCALE =                   39720.16
#OUTPUT_SCALE = -39720.16
INPUT_SCALE =                   10150.09
OUTPUT_SCALE = -10150.09
MIN_LIMIT =                     -7.0
MAX_LIMIT =                     7.0
FERROR = 1.0
MIN_FERROR = 0.01
HOME_OFFSET =                    0.0
HOME_SEARCH_VEL =                0.0
HOME_LATCH_VEL =                 0.0
HOME_USE_INDEX =                 NO
HOME_IGNORE_LIMITS =             NO
DEADBAND =                         0.000077
P =                              250
I =                              0
D =                                0.1
BIAS =                             0
FF0 =                              0
FF1 =                              1
FF2 =                              0.002

#add blank place holders for unused axis
[AXIS_3]
[AXIS_4]
[AXIS_5]
[AXIS_6]
[AXIS_7]

# Third axis W
[AXIS_8]

TYPE =                          LINEAR
HOME =                          0.0
MAX_VELOCITY =                  2.1
MAX_ACCELERATION =              24.0
PID_MAX_VEL =              2.2
BACKLASH = 0.000
INPUT_SCALE =                   10150.09
OUTPUT_SCALE = -10150.09
MIN_LIMIT =                     -7.0
MAX_LIMIT =                     7.0
FERROR = 1.0
MIN_FERROR = 0.01
HOME_OFFSET =                    0.0
HOME_SEARCH_VEL =                0.0
HOME_LATCH_VEL =                 0.0
HOME_USE_INDEX =                 NO
HOME_IGNORE_LIMITS =             NO
DEADBAND =                         0.000077
P =                              250
I =                              0
D =                                0.1
BIAS =                             0
FF0 =                              0
FF1 =                              1
FF2 =                              0.002 

----- Original Message -----
From: "Jeshua Lacock" <[email protected]>
To: "Enhanced Machine Controller (EMC)" <[email protected]>
Sent: Tuesday, September 8, 2015 8:30:06 PM
Subject: [Emc-users] Universal Stepper Driver 4th Axis Config

Greetings,

I am trying to add a 4th axis to my USC from Pico Systems.  My set of config 
files is at:

<http://3DTOPO.com/pico-univstep.tar.gz>

I defined the new axis as W and set it up the way the other axes are setup as 
far as I can tell. I didn’t set up the limit switches because I wasn’t sure 
what pins to use.

Anyhow, I can’t get Axis to launch with the W enabled. I get the error:

Can not find -sec APPLICATIONS -var DELAY -num 1 
HAL: ERROR: duplicate component name 'inihal'
ini_hal_init: ERROR: hal_init() failed
HAL: ERROR: duplicate component name 'inihal'
ini_hal_init: ERROR: hal_init() failed
HAL: ERROR: duplicate component name 'inihal'
ini_hal_init: ERROR: hal_init() failed
HAL: ERROR: duplicate component name 'inihal'
ini_hal_init: ERROR: hal_init() failed
HAL: ERROR: duplicate component name 'inihal'
ini_hal_init: ERROR: hal_init() failed
A configuration error is preventing LinuxCNC from starting.
More information may be available when running from a terminal.

I grepped around for ‘inihal’ but find no such term in my configs. Full error 
log is here:

<http://3DTOPO.com/wAxisErr.txt.gz>

BTW: I assume the 5V pin on the stepper drive goes to the 5V on the USC, but 
where does the enable go (been a while!)?


Thanks,

Jeshua Lacock
Founder/Engineer
3DTOPO Incorporated
<http://3DTOPO.com>
Phone: 208.462.4171


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