HP Tuners (www.hptuners.com) VCM Suite software gives professional tuners and enthusiasts people access to tuning parameters on Ford and GM vehicles. Currently VCM Suite supports a limited number of Ford vehicles (2004 – 2007 V8 F150s and 2005 – 2007 V8 Mustangs) but they are working on adding more vehicles to the database.

VCM Editor, the tuning portion of the suite, is a very powerful tool. Because the tool is so capable, it can therefore be dangerous in the hands of someone who isn't familiar with EFI tuning, especially Ford EFI tuning. For this reason, it is recommended to have a professional tuner set you up with a baseline tune, or spending time familiarizing your with the basics and spend a lot of time asking questions. Take your time and experiment with a few simple steps and try them out to see how they impact your vehicle before playing around with additional parameters.

VCM Editor isn't the first tuning software available to end users, but it does fill a niche quite nicely. It offers extensive reach, with access to hundreds of parameters available in the PCM, while presenting this in an interface that is easy to use with items grouped by type. VCM Editor uses a licensing technique which allows you to read and create as many tune profiles as you want from many vehicles. You purchase licenses to actually write the tunes out to a PCM. For instance, you can read your friends ECM to compare its base tune to yours without having to purchase a 2nd license, but if you wish to save modifications back out to his truck you'll have to pony up the bucks for a license.

HP Tuners also has a repository database of tunes but as someone who is experienced I recommend you stay away from using tunes of unknown quality made by people you don't know. You could easily end up causing catastrophic damage to your engine by putting an improper tune in it. At most you might want to use it simply to see what others are doing, perhaps getting a few ideas to try. VCM Editor does not use a handheld tuner. Instead it uses an OBDII to USB interface box.To program your truck you'll need either a laptop or a very long USB cable. The maximum USB cable length is 5 meters (about 16 feet, 5 inches). You can extend this with USB hubs but at some point this becomes unwieldy. For practical purposes if you don't have a laptop this product isn't for you. The software doesn't require much in the way of resources so if you can find an inexpensive, old Windows based laptop it should work for you. The first thing you'll need to do is read the OEM tune from your vehicle. Once you've done this the VCM editor will ask if you want to license it (ie, be able to write it out to the ECM). If you're just getting familiar with the software skip licensing the file.The first thing I did was start up the software and load up the PCM code for the 2007 F150 5.4L I'm going to tune. The PCM code is RXDF4B2. Tuning 101 and drive-by-wire throttle controls of the 2004 – 2008 F150 are very complex and beyond the scope of this article. Rather than showing all the changes (there can be literally hundreds in a good tune), I will focus only giving a very basic changes so you'll have an idea of how this software works.One of the handy things about the software is the window at the bottom of each section which gives handy tips about most available parameters. It won't teach you how to tune, but it will tell you what the table does in a very basic way. I recommend you take one of the tuning training courses available to get you up to speed or purchase a starter field from a reputable tuner. There are books available but none specific to the low level details of Ford tuning at this time.

Let's look at one of the most common changes: spark timing. Many beginners mistakenly change the "Global Spark Modifier" to change base spark timing. This is not something you want to do – at best it gives very gross control over spark advance and could very well get you results that are far less than desirable. It will not give you the results you're expecting. The most common place to address this is in the "borderline knock" table. Click "Engine", "Spark Control" and the "Borderline Knock". For 93 octane add about 6 degrees across the RPM range though you can add a couple of more degrees below 1000 rpm. Depending on fuel quality with some data logging you can get away with more timing advance, but 6 degrees is a good "safe" advance for 93 octane to start.

Here are the before and after screens:

Another thing to address is idle rpm when in gear. Move it up from 525 to 575. This will help throttle response and launch from a stop. For this, click "Engine" then "Idle" and change the "In Gear" idle RPM to 575. You should also raise neutral idle by a similar amount to keep the engine from making a large change in idle speed coming into or going out of gear. You can raise the idle even higher, say 600-620 rpm, but I don't recommend you do this if you do a lot of stop and go city driving because it can have a slight negative effect on fuel economy.

Next, you need to give the knock sensors the ability to add and pull timing more appropriately for 93 octane. Click "Engine", "Spark Control", "Spark Retard" and then "Knock Advance Limit vs RPM vs Load". Set all the fields to 7. Most PCM codes have a decent amount of spark retard they can pull. Make sure the "Spark Retard Limit" is -7 at the lowest loads and -12 starting from a load of .60. If not, adjust accordingly. If you have problems with consistent fuel quality you may want to increase these values. If you decide to decrease them (ie, the engine pulls out spark slower) make sure the advance rate isn't faster! Note that these are not the only tables needed to properly address spark advance and retard, but rather just a sampling of what's available in the software.

This is one of the areas you want to look at when data logging with HP Tuner VCM Scanner software that's part of the package VCM Suite package. Log the spark retard. Anywhere you see retard along the curve you'll need to pull some timing out via the borderline knock table. If all looks good, try adding a half degree where you can and log again. Repeat until you have optimal timing, just below where the PCM retards spark.

Here are the wide open throttle shift points. For naturally aspirated engines I prefer taking the 1-2 and 2-3 WOT shift points up to 5200 RPM and not touching the 3-4 WOT shift point. Shifting into 4th at WOT isn't going to happen on a stock, naturally aspirated truck, the speed is going to be much higher than the vehicle can go. For turbo and supercharged vehicles crank the WOT 3-4 shift way past any speed an F150 vehicle can reach in 3rd, such as 7000 RPM. The reason is that WOT 3-4 shifts are extremely rough on the transmissions and you don't want them to occur. There are plenty of stories out there of folks with improperly tuned truck grenading the transmission with a extremely high speed 3-4 WOT shift. The last thing you want to do on the track is lose your transmission at 140 mph! Additionally, with force induction engines you can also raise the shift points another 50 – 125 rpm to take advantage of the wider torque and horse power curves available.

Now, on to more features. When changing the shift points you need to make sure they do not "overlap" or you'll end up with a vehicle that does a lot of unnecessary shifting. Unfortunately, VCM Editor doesn't handle this in an easy way. The software allows you to pull up shift tables for each upshift and downshift, as well as graph these. Unfortunately I could not find a way to overlay the shift table graphs – this would have made the process much easier. Without it, pay special attention to the numbers. You may want consider loading the numbers into Excel and overlaying them as line graphs to make sure they shift points don't overlap. HP is aware of this issue and I've been told they are looking into solutions.


Without it, pay special attention to the numbers. You may want consider loading the numbers into Excel and overlaying them as line graphs to make sure they shift points don't overlap. HP is aware of this issue and I've been told they are looking into solutions.

VCM Editor allows you to graph most tables. Some, such as the upshift speed, are available as 2D line graphs. Where appropriate, some tables also have the ability to display 3D graphs.

In addition to the full spectrum of various engine, transmission and fueling controls VCM Editor gives you complete control of scalars and flags. For instance, you can change rev limiters, axle ratios, tire size, turn off individual OBDII codes if you plan to drive it off road and don't want the hassle of DTCs setting off the check engine light.

The software has pretty much everything a person needs to create a complete tune for their vehicle. The tables, flags and scalars available are also comprehensive enough for the professional tuner. The software allows you to purchase multiple vehicle licenses so the individual can use it with all his vehicles or the professional can take advantage of the year/model licensing to drive down the cost per vehicle tuned. In fact, you can tune as many 2008 F150s (and/or other year/models you license) was you want for only $699.00 and that includes the hardware.

The data logging software, VCM Scanner, is an extremely nice package when compared to its competition. For instance, the competition allows you to set up a couple dozen items to data log, the item colors and assign handful of them to digital "gauges", while line graphing the logged items along the bottom of the screen. VCM Scanner gives more detailed gauges and graphs:

VCM Scanner, when connected to your truck via a laptop and the OBDII interface, scans your PCM to obtain a list of standard OBDII signals it can log. Additionally, VCM Scanner allows you to custom log other items (PIDs) which are "non-standard" (such as Ford specific signals). Basically, any PID your vehicle can support it should be able to log. This has some positives and negatives. The positive is that you're not locked into only PIDs built into VCM Scanner's database. Any PID you know the number to can be data logged and there's no reason why you wouldn't be able to use this software to data log virtually any OBDII compatible vehicle, not just Fords. The negative is that you must define these, and none of the Ford specific signals are built in. You must have a signal reference available in order to define these. HP Tuners has told me this negative is something they are considering solutions for.
Other companies with data logging supply many Ford signals to log and that's a disadvantage to VCM Scanner, but I've also found with other software there are often signals not available and you cannot customize logging for signals the software doesn't know about. So, setup and data logging with VCM Scanner can be much more thorough but at the cost of some added complexity for non-OBDII standard PIDs.

Conclusions

VCM Suite gives great flexibility for those looking to make changes to their PCMs themselves, has a logical menu structure making things easier for new users and has a fairly complete set of parameters it allows the user to change. HP Tuners has been providing tools for GM users for quite some time and it was nice to see them make their products compatible with Ford PCMs. As the product matures and supports more Ford vehicles I have no doubt the company will become a major player, taking on companies such as SCT when it comes to tools for the end user. If you're willing accept the trade-off of not having a hand-held tuner you'll get a far more powerful tool in return, provided you have the time, talent and desire to learn the intricacies of Ford programming. Further, if you are having your car professionally tuned, and do not require a handheld, you do not have to pay for the handheld. It's not for everyone, but for those who feel the need to control the small details of how their vehicle operates is something worthy of serious consideration.

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AC yokes shall be capable of lifting:
1. 10 pounds with a 2 to 4 inch spacing.
2. 10 pounds with a 6 to 8 inch spacing.
3. 50 pounds with a 2 to 4 inch spacing.
4. 50 pounds with a 4 to 6 inch spacing.

DC yokes shall be capable of lifting:
1. 10 pounds with a 2 to 4 inch spacing.
2. 10 pounds with a 6 to 8 inch spacing.
3. 50 pounds with a 2 to 4 inch spacing.
4. 50 pounds with a 4 to 6 inch spacing.

T or F Technicians can wear photo chromatic lenses while performing a magnetic particle testing.

Who is responsible for the review of all written procedures or techniques?
1. A Level II or Level III.
2. A certified and qualified Level II or Level III.
3. A Level III
4. A certified and qualified Level III.

Procedures shall be submitted to the customer:
1. With the completion of the parts under inspection.
2. Prior to the testing of their parts.
3. Only upon request.
4. When a part has been rejected.

What type of magnetizing current can be used to perform testing to this procedure?
1. DC and AC only.
2. DC, AC and HWDC only.
3. DC, AC, HWDC, and FWDC only.
4. DC, AC, HWDC, FWDC and HWAC only.

When performing a magnetic particle test using fluorescent particles, the black light intensity should have a minimum intensity of:
1. 1000 uw/cm2 at the part surface.
2. 1,000 uw/cm2 at a maximum distance of 15 inches.
3. 1,000 uw/cm2 at a minimum distance of 15 inches.
4. 1,000 lux at the part surface.

If the results of any system performance test fail to meet the minimum requirements of this procedure:
1. A higher amperage setting may be used when the magnetic field is verified with a magnetic penetrameter.
2. The equipment can only be used if the magnetic field shows adequate field strength with a field indicator.
3. No part shall be processed until appropriate corrective action has been taken.
4. All results of the performance tests shall be recorded, filed and made available for review.

How often is a concentration test performed?
1. At the beginning of each shift.
2. Every 8 hours.
3. At the beginning of each shift and any time the magnetic particle machine has been turned off for longer than 15 minutes.
4. Only 1 and 2.

When a test is performed with a wet horizontal magnetic particle machine, the agitation of particles should be a minimum of:
1. 30 minutes.
2. 40 minutes.
3. 20 minutes.
4. 60 minutes.

A 100 ml centrifuge tube will have a fluorescent particle concentration of:
1. 1.2 to 2.4 ml
2. 0.2 to 0.4 ml
3. 0.1 to 0.4 ml
4. 1.0 to 2.0 ml

Why is the graduated portion of a centrifuge tube examined under a black light and white light?
1. This is performed in order to verify the particles still fluoresce.
2. Inspection for floating contaminants are easier to identify in the centrifuge tube.
3. Discoloration of particles can be identified and rejected if they do not fluoresce.
4. Inspection is performed for striations, banding or a difference in color.

If the L/D ratio is greater than 15:
1. The part should be inspected twice with a minimum of 10 percent overlap.
2. 15 should be used as the length when calculating the L/D ratio.
3. Ferromagnetic pole pieces of the same diameter shall be used to increase the L/D ratio.
4. A lower amperage can be used.

In all cases, fluorescent wet continuous magnetic particle testing shall be used for the testing of:
1. Class A components.
2. Petroleum hardware.
3. Aerospace components
4. Nuclear components.

In the residual testing method, when are the magnetic particles applied?
1. While the current is engaged.
2. Before the current is engaged.
3. Immediately after the current has been removed.
4. Immediately before the current has been removed.

When should the bath solution be changed?
1. When the contaminants exceed 30% or if the solution is noticeably fluorescent.
2. At intervals not to exceed three months.
3. At intervals not to exceed six months.
4. When the magnetic penetrameter no longer shows adequate indications.

When is corrective action needed during a water break test?
1. When an even coating in the test panel is present.
2. When the test panel shows signs of fluorescent particles under a black light.
3. Only when the solution shows signs of contamination.
4. When bare spots are present on the test panel.

Black light intensity from the face of the UV lens will be a minimum of:
1. 1200 uw/cm2
2. 1200 lux.
3. 1200 foot candles.
4. 1200 btu

T or F Magnetic particle machines shall be checked for internal shorting.

Prior to performing a fluorescent magnetic particle test, a technician should allow his or her eyes to adjust to a darkened area for a minimum of:
1. 5 minutes
2. 10 minutes
3. 1 minute
4. 2 minutes

When is pre-testing demagnetization required?
1. Always
2. Never
3. Only if prior operations have produced a residual magnetic field that may interfere with the testing.
4. Only of the part is placed in service next to magnetically sensitive gauges.

What type of cleaning methods are acceptable?
1. Detergents and solvents.
2. Vapor degreasing and wire brushing.
3. Blasting.
4. All of the above are acceptable.

All records of magnetic particle testing shall be kept on file for a minimum of:
1. 5 years
2. 7 years
3. 9 years
4. 11 years

How often is the ammeter accuracy calibrated?
1. Maximum of 3 months
2. Maximum of 6 months.
3. Maximum of 9 months.
4. Maximum of 1 year.

How often is the black light intensity checked?
1. Maximum of 1 day.
2. Maximum of 3 months.
3. Maximum of 8 hours.
4. Maximum of 2 days.

Small openings such as blind holes leading to the internal cores or passages shall be plugged or masked:
1. Unless otherwise specified by the customer.
2. Only when the customer requests plugging or masking.
3. Only when a dry magnetic particle test is performed.
4. Only when a wet magnetic particle test is performed.

To ensure detection of all discontinuities:
1. Parts should be inspected in at least two directions.
2. The highest possible amperage should be used.
3. Parts should be inspected with a black light.
4. Parts shall be magnetized in at least two opposite directions.

The magnetic field strength should be sufficient enough to:
1. Heat the part to curie temperature resulting in a high residual magnetic field.
2. Show all relevant discontinuities on a ketos ring.
3. Detect all indications, but not so strong that it may mask small indications.
4. Detect all indication on the field indicator.

Adequate field strength may be determined by:
1. Use of parts with known or artificial defects.
2. Use of a Hall-Effect probe gauss meter
3. Use of formulas provided in this procedure.
4. All of the above can be used.

Who is allowed to make accept/reject determinations?
1. The owner.
2. The level II technician
3. The level I technician
4. All of the above

When would a technician use this procedure?
1. When a magnetic particle machine is used for testing.
2. Whenever Mil-Std-1949 is referenced on the work instructions.
3. Whenever Mil-Std-1949 or ASTM-1444 is referenced on the work instructions
4. When no other procedure is available.

Calibration system requirements are performed according to:
1. ASTM E-1444
2. SNT-TC-1A
3. CP-1
4. Mil-Std-410

When magnetizing a component by passing the current directly through the part (head shot) the current shall be:
1. 300 to 800 amps per inch of part diameter
2. 300 to 800 amps per centimeter of part diameter.
3. 500 amps per inch of part diameter.
4. Determined with a Hall-Effect probe gauss meter.

For testing of inclusions in precipitation steels, higher currents may be used up to:
1. 500 to 1000 amps per inch of part diameter.
2. 1000 amps per inch of diameter.
3. 750 amps per inch diameter.
4. 1,200 amps per inch diameter.

The distance along the part’s circumference (ID) that can be effectively magnetized shall be taken as:
1. Two times the diameter of the conductor.
2. Three times the diameter of the conductor.
3. Four times the diameter of the conductor.
4. Five times the diameter of the conductor.

What level individual can make accept/reject determinations?
1. A Level I
2. A Level I under the direct supervision of a Level II or III.
3. A certified Level I.
4. A certified Level I under the direct supervision of a Level II or III.

What size are the smallest detectable defects that can be identified by this procedure?
1. It is not stated in the code.
2. 1/32 inch.
3. The smallest rejectable discontinuity specified in the acceptance criteria.
4. The smallest rejectable discontinuity specified in the rejection criteria.

The entire circumference of the part shall be tested by rotating the part. The required overlap field should be no greater than:
1. 10 percent
2. 15 percent.
3. 20 percent.
4. 5 percent.

For cable wrap or high-fill factor coils, the effective field extends:
1. 4 inches on either side of the coil center.
2. 7 inches on either side of the coil center.
3. 9 inches on either side of the coil center.
4. 11 inches on either side of the coil center.

The longitudinal formulas in this procedure only hold true if the L/D ratio is:
1. Less than 2 and greater than 15
2. Greater than 10 and less than 15
3. Greater than 2 and less than 15.
4. Greater than 2 and less than 20.

If the L/D ratio of 2 or greater cannot be achieved:
1. The part should not be tested with this procedure.
2. A shunt should be used to verify the magnetic field is adequate.
3. The part should be tested by the liquid penetrant method.
4. Ferromagnetic pole pieces of the same diameter shall be used to increase the L/D ratio.

The only time the residual testing method can be performed is when:
1. The customer specifically requests it.
2. This method can never be used.
3. The procedure requires a high amperage on a painted surface.
4. Fluorescent particles are used.

Demagnetization with an AC current and fixed coil should allow the part:
1. To be positioned in the center of the coil and moved to a point approximately 3 feet beyond the coil.
2. To be positioned as closely as possible to the side of the coil and moved to a point approximately 3 feet beyond the coil.
3. To be positioned in the center of the coil and moved to a point approximately 1 foot beyond the coil.
4. To be positioned as closely as possible to the side of the coil and moved to a point approximately 1 foot beyond the coil.

After demagnetization, the residual magnetic field shall not exceed:
1. 3 gauss anywhere on the part.
2. 2 gauss anywhere on the part.
3. 4 gauss anywhere on the part.
4. 5 gauss anywhere on the part.

Who has the responsibility to provide the accept/reject criteria for the part to be tested?
1. The contractor.
2. The testing laboratory.
3. The customer.
4. The procedure.

If the size or part configuration does not facilitate ink stamping:
1. Dying may be used.
2. Metal stamping may be used with the customers permission.
3. Red tagging acceptable parts may be used.
4. Etching may be used.

What are the minimum number of holes indicated when using wet suspension fluorescent particles with a central conductor and an amperage of 3,400?
1. 3
2. 4
3. 5
4. 6

All calibrated equipment shall have:
1. The calibration sticker placed on the calibration report form.
2. The calibration report on hand when testing is performed in the field.
3. A current calibration sticker affixed to it.
4. A calibration performed weekly.

Non-fluorescent magnetic particle testing will be performed with a visible light intensity of:
1. 100 lux
2. 1,000 foot candles
3. 10 foot candles
4. 1,000 lux

When performing a magnetic particle test using fluorescent particles, the background light intensity should be a maximum of:
1. 20 foot candles.
2. 100 lux.
3. 2 lux.
4. 2 foot candles.

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Welder qualifications are governed by the AWS/AASHTO D1.5 Bridge Welding Code and the Department’s Supplemental Specification 1011. Part B of SS1011 explains the administrative procedures required to qualify as an approved welder for the Ohio Department of Transportation. It is the individual welders responsibility to make sure all required samples, test data, and employment records are on file with the Office of Materials Management.

Qualified welders are listed in the Department’s Construction Management System.
Each welder should be checked to make sure they are qualified to weld on ODOT projects.
To confirm a welder is qualified for ODOT projects enter the Construction Management System and use the Fastpath WELD or LWELD to check for the following information:

Last Update: The welder’s qualification is in effect for 5 years unless the welder is not engaged in a given process for a period exceeding six months. Employment records are the welder’s responsibility to send to the Office of Materials Management. If the date listed on the CMS screen exceeds the six month period inform the welder they must update their work records. All welders are given a six month grace period if they have forgotten to send in their employment records. If the date listed on the CMS screen exceeds 1 year (required six month update plus the six month grace period) then the welder is no longer qualified and must retest.
Process: Welder’s must be qualified for the process for which they are welding in. Typical field welding processes are listed below:
SMAW (Shielded Metal Arc Welding) also known as stick welding
FCAW (Flux-cored arc welding) also know as wire welding
• Note: FCAW welding on main member structural steel requires Procedure Qualification testing by the Contractor per the AWS/AASHTO D1.5 Bridge Welding Code.
Weld Type: FI (Fillet welding) or GR (Groove welding)
Position: Welder’s must be qualified for the position in which they are welding.

F - Flat position
H – Horizontal position
V – Vertical position
OH – Overhead position


Any questions concerning welder qualifications can be directed to the Office of Materials Management, Structural Welding and Metals section.

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