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This exam assesses competency for journey-level industrial electricians. Topics include industrial power systems, control circuits, motor controls, PLCs, instrumentation, safety procedures, code compliance, and troubleshooting. Candidates must demonstrate the ability to perform industrial electrical work independently and safely.
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Question 1. Which of the following equations correctly represents Ohm’s Law for an industrial circuit? A) V = I × R B) P = V ÷ I C) I = V + R D) R = V ÷ P Answer: A Explanation: Ohm’s Law states that voltage (V) equals current (I) multiplied by resistance (R). Question 2. A motor rated at 7.5 kW operates on a 480 V three-phase supply. What is the approximate full-load current (FLC) using the formula I = P ÷ (√3 × V × PF), assuming a power factor of 0.9? A) 9.2 A B) 10.5 A C) 11.0 A D) 12.5 A Answer: C Explanation: I = 7500 W ÷ (1.732 × 480 V × 0.9) ≈ 10.6 A, rounded to the nearest whole number gives 11 A. Question 3. In a parallel-connected feeder, two conductors each have an ampacity of 150 A. What is the total ampacity of the feeder? A) 150 A
Answer: C Explanation: Parallel conductors add their ampacities, so 150 A + 150 A = 300 A. Question 4. According to NEC Article 100, the term “qualified person” means: A) Anyone who can read the NEC. B) A person with a recognized degree in electrical engineering. C) Someone who has the skills and knowledge to perform the work safely. D) Only a licensed electrician. Answer: C Explanation: A qualified person possesses the necessary skills and knowledge to perform the task safely, regardless of licensure. Question 5. When installing a grounding electrode system in a concrete-encased (Ufer) ground, the minimum exposed length of the rebar must be: A) 12 in. B) 6 in. C) 24 in. D) 18 in.
Question 8. For a three-phase, 4-wire wye-connected transformer, which conductor must be bonded to ground? A) All three phase conductors. B) The neutral conductor. C) The high-leg conductor only. D) No conductor; the transformer is isolated. Answer: B Explanation: NEC requires the neutral of a wye-connected secondary to be bonded to the grounding system. Question 9. The permissible voltage drop for a 120 V feeder supplying sensitive electronic equipment should not exceed: A) 1 % B) 2 % C) 3 % D) 5 % Answer: B Explanation: Industry practice limits voltage drop to 2 % for sensitive loads to maintain performance. Question 10. Which conduit type is allowed for direct burial in soil without a protective raceway?
C) PVC (Schedule 40) D) IMC Answer: C Explanation: PVC (Schedule 40) conduit is rated for direct burial per NEC. Question 11. A motor starter with an inverse-time breaker is protecting a 20 HP motor. The NEC-required breaker size, using Table 430.52, is closest to: A) 30 A B) 35 A C) 40 A D) 45 A Answer: C Explanation: A 20 HP motor at 460 V typically requires a 40 A breaker per Table 430.52. Question 12. In a Class I, Division 2 hazardous location, which type of wiring method is acceptable? A) Standard NM-B cable. B) Rigid metal conduit (RMC) with a grounding conductor. C) Flexible metal conduit without a bonding jumper.
Answer: B Explanation: Table 250.122 lists #12 AWG copper for a 30 A overcurrent device. Question 15. A conduit fill calculation shows that a 3/4-in. EMT can hold a maximum of 9 #12 THHN conductors. If you need to run 10 conductors, what is the correct action? A) Reduce conductor size to #14. B) Use a larger conduit. C) Bundle two conductors together. D) Increase conduit length. Answer: B Explanation: Exceeding fill limits is not permitted; the conduit must be upsized. Question 16. The Hawaii Administrative Rules (HAR) Title 16, Chapter 80, requires a Journey Worker to renew their license every: A) 1 year. B) 2 years. C) 3 years. D) 5 years. Answer: B Explanation: HAR mandates biennial (every two years) renewal for Journey Workers.
Question 17. In a motor control circuit, the control conductors are tapped off the motor branch circuit. According to NEC, the overcurrent protection for the control conductors must be: A) Same size as the motor OCPD. B) Not less than 125 % of the control load. C) Determined by Table 240.6. D) Protected by a separate fuse or breaker sized per Table 240.4(D). Answer: D Explanation: Control conductors must be protected by an OCPD sized per Table 240.4(D), independent of the motor OCPD. Question 18. Which of the following is the correct definition of “high-leg” (or “wild-leg”) in a 120/240 V split-phase system? A) The leg with the highest voltage to neutral. B) The leg with the lowest voltage to neutral. C) The leg that is grounded. D) The leg that supplies only 120 V loads. Answer: A Explanation: The high-leg is the phase that measures approximately 208 V to neutral in a 120/240 V system. Question 19. For a transformer rated 150 kVA, 480 V primary and 240 V secondary, the minimum primary overcurrent protection per NEC Article 450 is: A) 100 A
B) Within sight of the motor. C) No more than 30 ft away. D) At a remote control panel only. Answer: B Explanation: NEC 430.102 requires the disconnect to be “readily accessible” and within sight of the motor. Question 22. In a Class II, Division 1 hazardous area, which type of conduit is required for wiring? A) Rigid metal conduit (RMC). B) Flexible metal conduit (FMC). C) PVC conduit without a grounding conductor. D) Non-metallic raceway. Answer: A Explanation: Class II, Division 1 areas (combustible dust) require metal raceways such as RMC for protection. Question 23. A 250 kVA transformer has a secondary neutral that is not bonded. According to NEC, this is allowed only when the transformer is: A) Wye-connected with a grounded secondary. B) Delta-connected on the primary side. C) Connected to a separately derived system with an isolated neutral. D) Supplying a 120/240 V service.
Answer: C Explanation: An isolated neutral is permissible for separately derived systems where the neutral is not bonded to ground. Question 24. Which OSHA standard specifically addresses lockout/tagout (LOTO) procedures for industrial equipment? A) 29 CFR 1910. B) 29 CFR 1926. C) 29 CFR 1910. D) 29 CFR 1910. Answer: A Explanation: OSHA 1910.147 is the standard for controlling hazardous energy (LOTO). Question 25. When using liquid-tight flexible metal conduit (LFMC) for a vibrating motor, the maximum allowable length between supports is: A) 1 ft. B) 3 ft. C) 6 ft. D) 10 ft. Answer: C
Question 28. Which of the following is the correct method for calculating conduit fill for mixed-size conductors? A) Use the largest conductor size only. B) Add the cross-sectional areas of all conductors and compare to conduit’s allowable percentage. C) Multiply the number of conductors by the smallest conductor’s area. D) Use the average of the conductor sizes. Answer: B Explanation: Conduit fill is determined by summing the actual cross-sectional area of each conductor and ensuring it does not exceed the permissible fill percentage (40 % for more than 2 conductors). Question 29. For a 120/240 V single-phase service, the minimum size of the grounding electrode conductor (GEC) required for a 200 A service entrance is: A) #10 AWG copper. B) #8 AWG copper. C) #6 AWG copper. D) #4 AWG copper. Answer: C Explanation: Table 250.66 indicates #6 AWG copper for a 200 A service. Question 30. In a hazardous location, “explosion-proof” equipment must be installed with a sealed enclosure to prevent: A) Electrical shock.
B) Heat buildup. C) Migration of ignitable gases. D) Mechanical damage. Answer: C Explanation: Explosion-proof enclosures are designed to contain any ignition inside the device, preventing gas migration. Question 31. According to NEC, the maximum ambient temperature correction factor for conductors installed in a location with an ambient temperature of 40 °C (104 °F) when the base temperature is 30 °C (86 °F) is: A) 0. B) 0. C) 1. D) 1. Answer: B Explanation: Table 310.15(B)(2)(a) provides a correction factor of 0.95 for a 10 °C rise above the base temperature. Question 32. A motor starter’s contact rating must be at least what percentage of the motor’s full-load current? A) 75 % B) 100 % C) 125 %
Answer: C Explanation: Table 250.66 indicates #1/0 AWG copper for a 600 A OCPD. Question 35. In a 4-wire 120/240 V system, the “high-leg” voltage measured from the high-leg to neutral is approximately: A) 120 V B) 208 V C) 240 V D) 277 V Answer: B Explanation: The high-leg (wild-leg) in a 120/240 V system measures about 208 V to neutral. Question 36. Which NEC article governs the installation of industrial control panels? A) Article 300 B) Article 410 C) Article 430 D) Article 408 Answer: D Explanation: Article 408 covers switchboards, switchgear, and panelboards, including industrial control panels.
Question 37. The permitted voltage drop for a branch circuit supplying a lighting load is limited to: A) 2 % B) 3 % C) 5 % D) 10 % Answer: B Explanation: NEC recommends a maximum of 3 % voltage drop for lighting loads. Question 38. For a conduit system that contains 12 current-carrying conductors, what is the required derating factor per NEC Table 310.15(B)(3)(a)? A) 80 % B) 70 % C) 60 % D) 50 % Answer: C Explanation: For 10-20 conductors, the derating factor is 60 %. Question 39. Which of the following is the correct size of a copper equipment grounding conductor for a 60 A branch circuit protected by a 60 A breaker? A) #12 AWG B) #10 AWG C) #8 AWG
Explanation: Adjusted FLC = 30 A × 1.15 = 34.5 A. Question 42. When installing a cable tray, the NEC requires that the tray be grounded if the tray is made of: A) Aluminum. B) Steel. C) Plastic. D) Fiberglass. Answer: B Explanation: Metal cable trays (steel) must be grounded per NEC 392.30. Question 43. In a motor control center (MCC), the feeder conductors must be protected by a breaker sized at least: A) 80 % of the feeder ampacity. B) 100 % of the feeder ampacity. C) 125 % of the feeder ampacity. D) 150 % of the feeder ampacity. Answer: B Explanation: NEC 430.102 requires the feeder OCPD to be sized at not less than 100 % of the feeder ampacity. Question 44. Which of the following is the correct definition of “bonding jumper” per NEC Article 100?
A) A conductor that connects equipment to the neutral. B) A conductor that provides a low-impedance path between metallic parts and the grounding system. C) A flexible cord used for temporary connections. D) A conductor used only for grounding electrode systems. Answer: B Explanation: A bonding jumper creates a low-impedance path to ensure all metal parts are at the same potential. Question 45. The maximum number of conductors allowed in a 1-in. EMT for THHN/THWN-2 #12 wires, based on a 40 % fill, is: A) 9 B) 12 C) 15 D) 18 Answer: B Explanation: 1-in. EMT has an internal area of 0.304 in²; a #12 THHN has an area of 0.0133 in². 40 % of 0.304 in² = 0.1216 in², allowing about 9 conductors. However, using the NEC tables, a 1-in. EMT can accommodate up to 12 #12 conductors at 40 % fill. Question 46. For a 480 V three-phase motor with a locked-rotor current (LRC) of 150 % of FLC, the inverse-time breaker must be sized to withstand the LRC for at least: