AGL Component Library By Precision AGL Academy

Cable Test Point

A dedicated access point in the AGL series circuit that provides safe, convenient connection for test instruments to measure current, voltage, insulation resistance, and loop continuity. Typically located in junction boxes, handholes, or test panels, it enables rapid fault diagnosis, commissioning verification, and routine maintenance without disturbing the primary cable terminations.

AGL cable test point for measuring series circuit current, voltage and insulation resistance

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Overview

What Is It?

A Cable Test Point is a dedicated access point installed in the AGL primary or secondary circuit that allows test instruments to be safely connected for measurement and diagnostic purposes. It provides a convenient, reliable, and safe means of accessing the circuit conductors without needing to open cable joints, disconnect connectors, or interrupt service unnecessarily.

Key characteristics of cable test points include:

  • Accessible Terminals: Provides test terminals or probe points that are electrically connected to the circuit conductors, allowing measurement of current, voltage, resistance, and insulation integrity.
  • Safe Isolation: Designed with covers, test sockets, or probe ports that prevent accidental contact with live conductors while allowing authorised access for testing.
  • Waterproof Enclosure: Housed in an IP68-rated enclosure (junction box or handhole) that protects the test point from moisture, dirt, and mechanical damage in the airfield environment.
  • Multiple Connection Options: May include banana sockets, test probes, terminal blocks, or L-823 connectors (plug or receptacle) for connecting test instruments.
  • Clear Identification: Marked with circuit identification, voltage rating, and test point designation to facilitate correct instrument connection.

Test points are strategically located along the series circuit, typically at regular intervals, at circuit endpoints, at transition points between underground and elevated sections, and at key equipment interfaces. They are essential for efficient commissioning, troubleshooting, and periodic maintenance of AGL systems.

Purpose

Purpose & Function

The cable test point exists to make routine and diagnostic testing possible without the disruption a technician would otherwise face: opening a cable joint or disconnecting a live connector just to take a measurement risks introducing a new fault at exactly the connection that was previously working fine, and interrupts service to every fixture downstream on the loop. A dedicated, safely isolated access point removes that trade-off entirely.

By positioning these points at regular intervals, circuit endpoints, and key transitions, the design ensures that a fault anywhere along a long cable run can be localised by testing at successive points rather than requiring access at some arbitrary location the circuit happens to pass through. This structured access is what makes systematic commissioning checks and future fault-finding practical on an airfield where cable runs can extend for kilometres underground.

Application

Where Is It Used?

Cable test points are used throughout the airfield at strategic locations in the AGL system, including:

  • Primary Series Circuit Test Points: Installed in handholes or junction boxes along the runway and taxiway primary cable routes, providing access for current measurement, loop resistance testing, and insulation resistance checks.
  • CCR Output Test Points: Located at the CCR output panel or in the field near the CCR, allowing verification of output current and voltage during commissioning and maintenance.
  • Transformer Test Points: Some isolating transformers include built-in test points on the primary or secondary side for verifying transformer performance and secondary circuit integrity.
  • End-of-Loop Test Points: Installed at the end of a series loop (typically in a handhole at the far end of the runway or taxiway) to verify loop continuity and measure overall loop resistance.
  • Transition Points: At the interface between underground and elevated cable sections, test points allow verification of the connection integrity and insulation at the transition.
  • Junction Boxes and Splice Enclosures: Many junction boxes include test point terminals or probe ports for easy access to the circuit conductors without opening cable splices.
  • ALCMS and Monitoring Systems: Some test points are integrated with remote monitoring systems, providing continuous or periodic measurement of circuit parameters.

Test points are typically installed during initial construction and are documented in the as-built drawings, with their locations clearly marked on the airfield and in maintenance records.

Placement

Installation & Location

Test points are installed at the time of initial construction, typically within a handhole or junction box positioned at regular intervals along the primary series circuit, at the end of each loop, and at the transition between underground and elevated cable sections. Positioning inside a sealed, IP68-rated enclosure keeps the test terminals protected from moisture and dirt while still reachable by lifting a cover rather than excavating or disturbing the buried cable. Where a test point is associated with a specific piece of equipment — a CCR output or an isolating transformer — it's sited immediately adjacent to that equipment so the measurement taken reflects that specific interface rather than a length of cable further along the run. Locations are recorded in the as-built drawings and marked at the airfield surface, since a test point that can't be found again defeats the purpose of having installed it in the first place.

Function

How Does It Work?

A cable test point provides a safe and convenient interface between the circuit conductors and test instruments. Its design ensures that measurements can be taken accurately and safely without disturbing the circuit terminations:

  • Circuit Connection: The test point terminals are permanently connected (tapped) to the circuit conductors using reliable, low-resistance connections. For primary circuits, the connection is typically made by splicing or tapping the test point into the main conductor using approved methods.
  • Isolation and Safety: The test point is housed in a secure enclosure with a cover or locking mechanism. Access requires a tool or key, preventing unauthorised contact with live conductors. Some test points include fuse protection or current-limiting resistors to protect the test instrument and the operator.
  • Test Instrument Connection: Test instruments (multimeters, loop resistance testers, insulation testers, current clamps) are connected to the test point using appropriate leads, probes, or connectors. The test point may include:
    • Banana Sockets (4mm): Industry-standard test sockets for connecting multimeter leads.
    • Test Probe Ports: Sealed ports that allow probe insertion for direct contact with the circuit conductors.
    • L-823 Connectors: A plug or receptacle that allows connection of a dedicated test lead assembly.
    • Terminal Blocks: Screw terminals that accept ring or spade lugs from test leads.
  • Measurement Types: The test point enables various measurements:
    • Loop Current: Measuring the series circuit current with a clamp meter or inline ammeter.
    • Voltage Drop: Measuring voltage across the loop or across individual segments to identify high-resistance connections.
    • Loop Resistance: Measuring the total resistance of the series loop to verify conductor integrity and connection quality.
    • Insulation Resistance: Measuring the insulation resistance between conductors and earth to detect cable damage or moisture ingress.
    • Continuity: Verifying that the circuit is complete and that there are no open-circuit faults.
Architecture

System Architecture & Control Logic

A test point carries no logic of its own — it is a permanently wired-in access point that makes the loop-level fault model used across the AGL system practical to act on. When the ALCMS reports a loop voltage anomaly, that report identifies the circuit, not the location of the fault; test points spaced along the loop (often co-located with, or built into, junction boxes) are what let a technician bisect the loop with a resistance or insulation-resistance reading, halving the search each time, without breaking a single splice or disturbing a fixture connection. Because the test point taps the conductor directly rather than through any active sensing electronics, it reads exactly what the CCR and regulator monitor read at that point in the loop, so a discrepancy between a test-point measurement and the CCR's own reported loop parameters localises the fault to one side of that test point or the other. This makes the test point the field-level counterpart to the CCR regulator monitor's control-room-level view of the same circuit.

Process

Test & Measurement Path

Circuit Conductors
→
Tapped Connection
Low-resistance splice/tap
→
Secure Enclosure
Key/tool access only
→
Test Instrument Connected
Banana sockets, probe ports, L-823, or terminal blocks
↓
Measurements Taken
Loop current, voltage drop, loop & insulation resistance, continuity
→
Circuit Verified / Fault Isolated
Without disturbing terminations
Construction

Physical Construction

The test point is built around a set of test terminals — banana sockets, an L-823 connector, or a small terminal block — potted or moulded into a polycarbonate, PVC, or brass housing that isolates the live terminals from accidental contact while still allowing a test probe to be inserted. Internal connection to the primary or secondary conductor is made by a crimped, soldered, or compression tap, chosen so the tap itself is at least as reliable as the cable splice it's placed alongside, since a failed tap connection would introduce a fault into the circuit it was meant to help diagnose. The housing is gasket-sealed to achieve an IP68 rating, allowing the test point to be installed inside a handhole or junction box that may see standing water, and shrouded or recessed sockets prevent inadvertent contact with the primary circuit's several-kilovolt open-circuit voltage when the point isn't in active use. Where fuse protection is fitted, it sits inline between the tap and the test terminals in its own small compartment, replaceable without disturbing the tap connection to the main conductor.

Specification

Technical Parameters

ParameterTypical Value
Voltage Rating5kV (primary), 600V (secondary) — insulation rating
Current Rating6.6A or 20A (series circuit rating)
Connection TypeBanana sockets, test probes, L-823 connector, terminal blocks
Enclosure MaterialPolycarbonate, PVC, or brass with IP68 rating
Protection ClassIP68 (submersible, continuous)
Operating Temperature-40°C to +85°C
Conductor ConnectionCrimped, soldered, or compression tap to primary/secondary conductor
Test Lead Compatibility4mm banana plugs, L-823 plugs, or custom test leads
Safety FeaturesShrouded sockets, keyed access, fuse protection (optional)
Cable Size Compatibility6 AWG to 2 AWG (primary); 1.5mm² to 6mm² (secondary)
StandardsIEC 61010, IEEE 404, FAA AC 150/5345-26
Power Supply

Electrical Requirements

RequirementTypical Value
Circuit Rating5kV primary / 600V secondary insulation, 6.6A or 20A series circuit current
Conductor TapCrimped, soldered, or compression tap to the primary/secondary conductor
Isolation from Live PartsShrouded sockets and keyed access to prevent accidental contact while live
EnclosureIP68-rated junction box, handhole, or test panel
Earthing/GroundingEnclosure and any exposed metalwork bonded to airfield earth grid
Fuse ProtectionOptional inline fuse on test leads for instrument protection
Power SourceNot independently powered — taps the existing primary/secondary circuit conductors
Compliance

Applicable Standards

IEC 61010

Safety requirements for electrical equipment for measurement, control, and laboratory use

IEEE 404

Standard for extruded and laminated dielectric shielded cable joints — relevant background for testing shielded circuits in this voltage range

FAA AC 150/5345‑26

Specification for L‑823 Plug and Receptacle, Cable Connectors, where the test point uses an L‑823 interface

ICAO Annex 14

General requirements for AGL circuit maintenance and testing access

Prerequisites

Installation Requirements

Handhole/Junction Box Positioning
Civil

Position the test point at regular intervals along the primary series circuit, at the end of each loop, and at the transition between underground and elevated cable sections, within a handhole or junction box.

Equipment-Adjacent Siting
Civil

Where the test point is associated with specific equipment — a CCR output or an isolating transformer — site it immediately adjacent so the measurement reflects that interface rather than a length of cable further along the run.

Conductor Connection
Electrical

Crimp, solder, or compression-tap the test terminal to the primary or secondary conductor, matching the connection method to the cable size.

IP68 Enclosure Sealing
Electrical

Seal the test point within its IP68-rated enclosure so the terminals stay protected from moisture and dirt while remaining reachable by lifting the cover.

Surface Marking
Documentation

Mark the test point's location at the airfield surface so it can be found again without excavating or disturbing the buried cable.

As-Built Location Recording
Documentation

Record the test point's position in the as-built drawings.

Insulation/Continuity Baseline Check
Documentation

Take and record a baseline reading through the new test point before it's relied on for future fault-finding.

Pre-Energisation Sign-off
Documentation

Record connection method, enclosure seal, and baseline reading as-built before the site is closed.

Verification

Testing & Commissioning

Conductor Tap Connection Check
Installation

Confirm the test point's tap connection is correctly terminated and torqued to the circuit conductor before the joint is closed up.

Insulation Resistance Test
Pre-Energisation

Megger through the test point to confirm it has not degraded the circuit's overall insulation resistance.

Fuse Protection Check
Pre-Energisation

Confirm fuse rating and function match the design, where a fuse is fitted to protect the test tap.

Socket/Probe Contact Verification
Final Acceptance

Connect test instrument probes and confirm a stable, repeatable reading with no intermittent contact.

Safety Shroud & Access Verification
Final Acceptance

Confirm the shroud or cover excludes accidental contact with live conductors while still allowing safe, quick test access.

Documentation & As-Built Sign-off
Final Acceptance

Record insulation resistance and test point location in the commissioning dossier.

Upkeep

Inspection & Maintenance

Socket & Probe Contact Check
Annual

Inspect banana sockets and test probe contacts for corrosion or wear so test readings remain accurate and reliable.

Seal & Enclosure Inspection
Annual

Check the polycarbonate, PVC, or brass enclosure and its seals to confirm the rated IP68 protection is intact.

Conductor Tap Connection Check
Annual

Re-verify crimped, soldered, or compression tap connections to the primary/secondary conductor to confirm low-resistance, secure contact.

Insulation Resistance Test
Annual

Megger-test the test point connection to confirm insulation resistance stays above the minimum, flagging moisture ingress before it causes a fault.

Safety Shroud & Access Check
Annual

Confirm shrouded sockets and keyed access covers remain functional so live testing can only be performed by authorised personnel with the correct leads.

Fuse Protection Check
Annual

Where fuse protection is fitted, verify the fuse rating is correct and undamaged before the test point is next used.

Labelling & Circuit Identification Check
Annual

Confirm the test point's circuit identification remains legible so technicians select the correct point during fault-finding.

Pit/Surround Condition Check
Semi-annual

Check the surrounding pavement or pit for standing water, debris, or settlement that could affect access or seal integrity.

Field Notes

Common Field Issues

Corrosion of Test Terminals

Despite protective enclosures, test terminals can corrode over time, especially in coastal or chemically aggressive environments. Regular inspection and cleaning of terminals, along with application of corrosion-inhibiting compound, are recommended.

Water Ingress into Test Point Enclosure

If the enclosure cover is not properly sealed or the gasket is damaged, moisture can enter and cause corrosion or short circuits. Inspect seals regularly and replace if damaged.

Loose or High-Resistance Connections

The test point's connection to the circuit conductor can become loose over time due to vibration or thermal cycling, resulting in high resistance and measurement errors. Periodically verify the connection integrity and tighten as required.

Inaccessible Test Points

Test points that are buried under asphalt, overgrown with vegetation, or obscured by equipment can be difficult to locate and access. Maintain clear access routes and keep test point locations documented and marked.

Incorrect Test Equipment Connection

Using the wrong test leads or connecting to the wrong terminals can damage the test instrument or give incorrect readings. Ensure that test leads are correctly rated for the circuit voltage and that the correct terminals are used.

Loss of Identification Markings

Test point identification labels can fade or become detached, leading to confusion during maintenance. Use durable, UV-stabilised labels and periodically reapply as needed.

Inadequate Test Point Density

If test points are spaced too far apart, it may be difficult to locate the exact location of a fault. Install test points at regular intervals (typically every 300-500m) and at all key circuit transition points.

Diagnostics

Troubleshooting Guide

Erratic or Drifting Insulation Resistance Readings
Likely Cause
Corroded test terminals are introducing contact resistance that varies with cleaning or weather, rather than a genuine change in cable insulation.
Diagnostic Steps
Inspect terminals for visible corrosion or oxidation before connecting test leads; clean and re-test to see if the reading stabilises; compare against the last recorded baseline for that test point.
Corrective Action
Clean terminals and apply a corrosion-inhibiting compound, and re-test; if drift persists after cleaning, investigate the cable/circuit itself rather than the test point hardware.
Corrosion or Moisture Found Inside the Enclosure
Likely Cause
A damaged or improperly seated gasket has allowed water ingress into the test point enclosure.
Diagnostic Steps
Inspect the enclosure cover, gasket, and seal for damage or improper seating; check for standing water, staining, or corrosion inside.
Corrective Action
Replace the damaged gasket, dry out the enclosure, clean any corrosion from terminals, and confirm the cover seats and seals correctly before closing up.
Measurement Results Inconsistent with Known Circuit Condition
Likely Cause
A loose or high-resistance connection at the test point terminal itself, caused by vibration or thermal cycling, rather than a fault in the circuit under test.
Diagnostic Steps
Check terminal tightness and connection integrity before relying on the measurement; retest after re-tightening to see whether the reading changes significantly.
Corrective Action
Re-terminate the connection to the correct torque, and re-run the measurement; treat any reading taken before this check with caution.
Test Point Cannot Be Located in the Field
Likely Cause
The test point is buried under asphalt, overgrown, or obscured by parked equipment, and its documented location doesn't match what's found on site.
Diagnostic Steps
Check the as-built drawings and test point location records against GPS coordinates or physical markers; walk the expected location with a cable locator if the point is suspected buried.
Corrective Action
Clear vegetation or request equipment be moved to restore access, and update location records/markings if the documented position was inaccurate; consider adding a surface marker if none exists.
Instrument Reads Zero, Overload, or Damages on Connection
Likely Cause
The wrong test leads were used for the circuit voltage, or the leads were connected to the wrong terminals on the test point.
Diagnostic Steps
Before reconnecting, verify the circuit voltage rating against the test lead rating; confirm the terminal layout against the test point's labelling or wiring diagram.
Corrective Action
Use correctly rated test leads and confirm terminal identification before reconnecting; have the test instrument checked for damage if an incorrect connection was made under load.
Reliability

Failure Modes & Root Causes

Terminal Corrosion
High Severity
Root Cause
Moisture ingress through a degraded gasket, condensation cycling inside the enclosure, or dissimilar-metal contact at the terminal without adequate anti-corrosion compound.
Effect
Elevated contact resistance that produces erratic or drifting insulation-resistance readings, undermining confidence in the recorded test history.
Detection Method
Visual inspection of terminals at each scheduled test, comparison of readings against the recorded baseline, and re-test after cleaning to confirm whether drift resolves.
Enclosure Gasket / Seal Failure
High Severity
Root Cause
Gasket material perishing with age and UV/temperature cycling, an improperly seated cover after a previous test, or physical damage from mowing or plough contact.
Effect
Water and debris ingress into the enclosure, accelerating terminal corrosion and risking a short or ground fault at the test point.
Detection Method
Visual check of the cover, gasket, and seal for damage or improper seating, and inspection for standing water or staining inside the enclosure during scheduled maintenance.
Loose or High-Resistance Terminal Connection
Medium Severity
Root Cause
Vibration or thermal cycling gradually loosening the terminal fixing, or the connection was not torqued to specification at installation.
Effect
Measurement results that don't match the known circuit condition, leading to unnecessary follow-up investigation or a missed genuine fault.
Detection Method
Physical check of terminal tightness before relying on a reading, and re-test after re-tightening to confirm whether the result changes significantly.
Enclosure Physical Damage
Medium Severity
Root Cause
Impact from mowing equipment, vehicle traffic, or snowploughs, and cracking of the enclosure body from repeated freeze-thaw cycling.
Effect
Compromised weatherproofing and mechanical protection of the terminals, and a potential trip or access hazard in the surrounding turf or pavement.
Detection Method
Visual inspection of the enclosure body and cover for cracks or impact damage during routine patrol and each scheduled test visit.
Location Record Drift
Low Severity
Root Cause
As-built records not updated after a rework, or the test point becoming buried, overgrown, or obscured by later construction or landscaping.
Effect
Test point cannot be located in the field, delaying scheduled testing and increasing labour time for routine maintenance.
Detection Method
Cross-check of as-built drawings and location records against GPS coordinates or physical markers, and a cable locator sweep if the point is suspected buried.
Precautions

Safety & Operational Notes

Series Circuit Isolation
Electrical Safety

The test point sits on a constant-current series loop that can carry several kV. De-energise and lock out the CCR, then verify zero energy before opening the enclosure or disconnecting terminals.

Airside Work Coordination
Operational

Where the test point lies within the movement area or its safety zone, obtain ATC/airside coordination and a NOTAM as needed, and keep personnel and vehicles clear of active runway or taxiway operations.

PPE & Insulated Tools
Personnel Safety

Use insulated tools and appropriate PPE when connecting or disconnecting test leads on a series circuit, and confirm the enclosure is bonded/grounded per the electrical design before closing it up.

FOD Control at the Enclosure
Operational

Keep tools, fasteners, and the cover gasket accounted for at all times when the enclosure is open, and confirm nothing is left loose in the surrounding turf or pavement before leaving the site.

Confirm De-Energised Before Megger Testing
Electrical Safety

Never connect a megger or insulation tester to a live circuit; verify isolation at the test point itself immediately before testing, even if the circuit was switched off elsewhere.

Discharge Stored Energy
Electrical Safety

Allow for and confirm discharge of any residual capacitive or inductive energy in the loop before handling terminals, particularly after a megger test or on long cable runs.

Secure Enclosure After Testing
Compliance

Reinstate the gasket and cover correctly and confirm the enclosure is properly seated and secured before re-energising, so weatherproofing and mechanical protection are not left compromised.

Restore to Compliant State
Compliance

Do not leave the circuit de-energised or the loop open longer than necessary; verify insulation resistance and continuity are within tolerance before restoring power and closing out the work.

Field Insight

Engineering & Expert Notes

Undocumented Test Points Cost Hours During Fault-Finding
Process

A test point that isn't accurately marked on the as-built loop drawing forces a technician to hunt for access during a fault, right when time matters most. Keep test point locations and their loop segment mapping current whenever circuit work changes the layout.

A Flooded Test Point Pit Reads Like a Cable Fault
Diagnostics

Standing water inside a test point enclosure can depress an insulation resistance reading enough to suggest a cable fault when the actual issue is water at the connection itself. Check and, if needed, drain the enclosure before condemning the cable based on a poor reading taken there.

Use Test Points to Bracket a Fault, Not Just Confirm One
Technique

Testing from intermediate test points along a loop, rather than only from the two ends, narrows a suspected fault to a shorter cable segment far faster than end-to-end testing alone. Plan test point spacing with fault-bracketing in mind, not just circuit access.

Corroded Terminals Inside the Test Point Add False Resistance
Maintenance

Corrosion on the terminals inside a test point enclosure adds resistance that has nothing to do with the cable being tested, and can produce a misleadingly poor reading. Clean terminal surfaces as part of routine test point maintenance, not only when a reading looks suspicious.

Confirm Isolation at the Test Point Itself, Not Just Upstream
Electrical Safety

Verifying isolation at the CCR alone doesn't guarantee zero energy at a downstream test point if an unexpected cross-connection or backfeed exists on the loop. Always confirm zero energy directly at the test point before working on it, regardless of the upstream isolation status.

Log Readings Against the Specific Test Point ID
Compliance

Tying insulation and continuity readings to a specific test point ID, rather than a general loop description, makes it possible to see whether degradation is concentrated in one cable segment or spread across the whole loop when reviewing trend data later.

Quick Answers

Frequently Asked Questions

Short answers about cable test points: what they do, ratings, siting, standards, maintenance and common faults.

Q1What is a cable test point?

A cable test point is a dedicated access point in an AGL primary or secondary circuit that lets test instruments be connected safely for measurement and diagnosis. It gives access to the circuit conductors without opening cable joints, disconnecting connectors or unnecessarily interrupting service.

Q2Why not just open a joint or unplug a connector to test?

Doing so risks introducing a new fault at a connection that was working fine, and interrupts service to every fixture downstream on the loop. A dedicated, safely isolated access point removes that trade-off.

Q3What can be measured at a test point?

Current, voltage, loop resistance and insulation resistance. Primary circuit test points give access for current, loop resistance and insulation checks, and CCR output test points allow output verification during commissioning and maintenance.

Q4Where are cable test points installed?

In handholes or junction boxes at regular intervals along the primary series circuit, at the end of each loop and at transitions between underground and elevated cable, plus at the CCR output panel. Some isolating transformers include built-in test points. They are put in at initial construction.

Q5What are the ratings?

5 kV insulation rating on the primary and 600 V on the secondary, for 6.6 A or 20 A series circuits, in an IP68 enclosure of polycarbonate, PVC or brass. Cable compatibility is 6 AWG to 2 AWG (primary) and 1.5 to 6 mm² (secondary).

Q6How is a test point made safe?

Shrouded sockets and keyed access covers prevent accidental contact while live, so testing can only be done by authorised personnel with the correct leads. An optional inline fuse on the test leads protects the instrument.

Q7What connections does it use?

Banana sockets (4 mm plugs), test probes, L-823 connectors or terminal blocks, tapped to the conductor by crimp, solder or compression. It is not independently powered.

Q8Which standards apply to cable test points?

The main references are IEC 61010, IEEE 404 (shielded cable joints), FAA AC 150/5345-26 where the test point uses an L-823 interface, and ICAO Annex 14. Always verify the current edition and your approved requirements.

Q9How often should a cable test point be inspected?

Typically annually: socket and probe contacts, seal and enclosure condition, conductor tap connections, insulation resistance, safety shroud and access, and fuse protection where fitted. Your approved maintenance programme takes precedence.

Q10Why are insulation resistance readings erratic or drifting?

Corroded test terminals may be adding contact resistance that varies with cleaning or weather, not a real change in cable insulation. Clean the terminals, apply corrosion-inhibiting compound and retest, and only investigate the cable itself if drift persists.

Q11Why is there moisture or corrosion inside the enclosure?

A damaged or badly seated gasket has let water in. Inspect the cover, gasket and seal, check for standing water, and replace the seal before returning the test point to service.

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