New configuration installed without problems but won't run linuxcnc

We have a custom kinematics file for a 6-axis ABB IRB 2000 model that was compiled with no errors, and also altered .ini and .hal files installed but when we try running linuxcnc with this configuration it creates a problem with loaded realtime modules. This is running in a computer with Ubuntu 10.04.4 LTS and realtime kernel 2.6.32-122-rtai, which has been working with no problems with other custom configurations and kinematics (LinuxCNC version 2.5.4). The config files are attached below.
Running linuxcnc with the command:
> linuxcnc abbirb.ini
we get the following log:
> LINUXCNC - 2.5.4
>Machine configuration directory is '/home/asea/Documents/Files/Source/build/configs/abbirb'
>Machine configuration file is 'abbirb.ini'
>Starting LinuxCNC...
>abbirb.hal:4:module 'abbirb' not loaded
>Shutting down and cleaning up LinuxCNC...
>ERROR: Module hal_lib is in use by abbirb
>ERROR: Module rtapi is in use by hal_lib
>ERROR: Module rtai_math is in use by rtapi
>ERROR: Module rtai_sem is in use by rtapi
>ERROR: Module rtai_fifos is in use by rtapi
>ERROR: Module rtai_sched is in use by rtapi,rtai_sem,rtai_fifos
>ERROR: Module rtai_hal is in use by rtapi,rtai_sem,rtai_fifos,rtai_sched
>Cleanup done
...
We looked into the kernel modules and the module for abbirb.ko exists, but loading it manually with insmod doesn't seem to work and even though these errors occur, the module appears as loaded when we check with lsmod.
We have also tried to run linuxcnc after unloading the abbirb module with rmmod and the error is different, with the following line:
>insmod: error inserting '/usr/realtime-2.6.32.122-rtai/modules/rtai_hal.ko': -1 File exists
After this we tried building from scratch but the error persists. And yes, our version is very old but we also tried several times with the last build available for ubuntu with rtai but we couldn't get linuxcnc to work because of the package dependencies. So we decided to use the linuxcnc version that already works with other custom configurations. Please help.