1. Test Plan
Subject: Life time test – Insperation lungs
Responsibility: Anan Halabi & Gengrinovich Semion
Description of the Unit under Test:
1. Superfobic
2. G3
General:
1 Recently we expose to uncontrolled spray phenomena from PHs on Inspiration
machine (XP2700).
2 Possibility of cause for this problem is high concentration of gas on ink.
3 This problem is characterized to Fine Press printing mode.
4 Current solution to this problem is adding lungs and SW compensation.
5 Lunges component is acquired from to two supplies: Superfobic and G3.
6 Qualification process of this solution requires proving the reliability of these types
of lungs according to the usage model in our machines.
7 Lifetime expected from the lunges is 5 years.
Test Objective:
To prove with a reliability level of 95% at a 70% confidence level that the
lung can control gas concentration less than 5 PPM for an amount of at
least 23k[liters].
Failure mode expected:
8 Blocking pores on membrane of the lung in operating mode.
9 Breakthrough of membrane – we will expose of ink drawing by vacuum pipe.
10 Blocking pores on membrane of the lung in non operating mode in case ink
standing.

2. Pass/Fail Criteria:
11 DO Level on Ink - concentration of Gas on ink over time. Unites[PPM]
12 If DO level on Ink is bigger than 5 PPM, failure is exposed.
13 Potential causes for high rate of PPM: Blocking pores of membrane, level of
vacuum change over time or breakthrough of membrane.
14 Each type of cause should be distinguished clearly in order to try separate different
types of failure modes. This section should be covered by the jig design
15 Breakthrough of membrane- visual
16 Blocking pores of membrane- Failure analysis.
Qual -Pre-testing:
17 DO level range which solve the spray problem: according to experiments
performed by HISS Team the range which is acceptable is 3-5 PPM, which is
supported by vacuum 0.6-0.8[bar]. In the jig the vacuum is defined to 0.8[bar]
18 Pressure drop test
19 We gain knowledge about flow rate related to pumps- one month usage we expose
to 12% degradation. In order to keep rate of flow 375[cc/min] we should begin
with 420[cc/minute].
Tests during the experiment:
20 Test of DO level - Measuring once a week. Two valves should be constructed on
the jig, one is before the lung and the other after for taking sample of ink (each
sample is around 70 cc).
21 DO level – will be measuring with tool Oxy Guard in two points before and after
the lung:
21.1 Turn off the pump
21.2 Close main valve of the sub system
21.3 Open valve (or before the lung or after the lung)
21.4 Filling measuring tube with 70cc of ink,
21.5 Immerse the tool inside the glass
21.6 Rotate for one minute or due to stabilization of level DO on the screen
of the tool.
22 Flow measurement – will be conducted once a week for all lungs trough the valve
that locating after the lung.
22.1 Turn off the pump
22.2 Close main valve of the sub system
22.3 Put measuring tube under the second valve that located after the lung
22.4 Turn on the pump and wait for one minute
23 Each test should contain 3 measurements for DO and flow.
24 Ink testing properties once a week- from each main tank of the sub-system. The
sample will be conducted with injector. Quantity of ink will be defined by
chemistry lab.

3. 25 Visual testing of vacuum pressure will be conducted once a day by the operator. In
case there is a decrease of vacuum to 0.6 bar - alert.
26 Visual testing of positive pressure will be conducted once a day by the operator. In
case there is a decrease to TBD bar - alert.
Environmental Conditions:
Condition
Control/
Measurement
Comment
Ambient Temperature Normal Usage
Test Equipments- jig:
27
C
onditions on which the lungs work:
The difference between DO Level before lungs no more than 1 [PPM]
Maximum DO level can not be more than 8[PPM]
Sub- system

4. Flow rate through each lung will be the same – 400cc/min. In case of
deterioration of flow rate we will increase voltage supply to the pump. (In
initial condition we decrease the voltage supplying for the pumps)
Max flow difference – [TBD]
Max ink Temp-[TBD]
Max vacuum difference-[TBD]
Scenario and Response:
28 Level of PPM before and after lung is equal-what action should be done?
28.1 Check if supplying positive pressure work.
28.2 If supplying positive pressure work properly then bring the lung to
HISS laboratory for additional checking.
29 Ink test is fail
29.1 Removing all the ink from main tanks and filling with new one.
30 Difference between sub-systems is bigger than 1 PPM-
30.1 TBD
31 Instability on Flow rate –
31.1 TBD
Usage model- Lunges
lunges usage model
Pump Operation lung
Working day
per month
Working month
per year
Expected
life of
pump Ink/Life
Usage
model
liter/day liter/day day/month Months/year
18 18 22 12 5 23760 23760
32 In normal usage operating pump rate is 150 [cc/minute], 9 [liter/hour].
33 In lifetime test it is acceptable to accelerate the duty cycle of the component by
2.5.
34 Factor accelerating is 2.5 leads to operating rate 375[cc/minute], 22.5[liter/hour]
35 Continues Operating mode is more difficult for lung than operating by ON/OFF
cycle.
36 Blocking pores of membrane failure mode can be evaluated in two cases:
operating mode and non operating mode when there is Ink inside the lung.
37 Lung operate in case the pump supply ink to it.
38 We assume from the Lifetime test of pumps that the pump is operating 60% of the
time and 40% not operating.60% of 24 hours a day=14 hours and non-operating is
10 hours.
39 In order to include in our test cycle operating mode and non-operating mode and
still keeping difficult work mode: continuous operating 16 and non operating 8
hours.
40 22.5[liter/hour]*16[hours] =360[liter/day].
41

5. 42 Assuming Weibull Distribution, beta=2, C.L=70% and Reliability 95%, 0 failures
expected.
Target ink
liter- test
7 43,509 3.90
8 40,699 3.65
9 38,371 3.44
10 36,402 3.26
units
Test Duration
[month]
43 In order to prove 23k[liter] with reliability 95%@C.L70% , 8 unites under test we
need to supply to the lung 40.69k[liter].
44 Test duration:
45 From experience we gain on pump lifetime test we suggest to enlarge the sample
size test to minimize the uncertainty in estimating the parameters of the
Distribution on one hand and shorten the duration of the test from 3 and half
months to 2 months and half:
Units
Target ink Test Duration
[month]liter- test
7 43,509 3.90
8 40,699 3.65
9 38,371 3.44
10 36,402 3.26
11 34,708 3.11
12 33,230 2.98
13 31,927 2.86
14 30,765 2.76
15 29,722 2.66
46 Trade-off between cost of components and test duration cost and add value related
acknowledge gained with large sample should be taken in consideration.

6. Safety requirement: TBD
Applicable industry standards: TBD
Test and monitoring equipment:
47 Flow-accuracy measurement 25 [cc]
48 Tool for PPM- accuracy measurement 0.05 [PPM]
49 Positive pressure- accuracy measurement 0.01[bar]
50 Vacuum pressure- accuracy measurement 0.01[bar]
Reporting-
Process of weekly report: measurement file, responsibility Semion.
Monthly analysis - Responsibility Anan.

7. Safety requirement: TBD
Applicable industry standards: TBD
Test and monitoring equipment:
47 Flow-accuracy measurement 25 [cc]
48 Tool for PPM- accuracy measurement 0.05 [PPM]
49 Positive pressure- accuracy measurement 0.01[bar]
50 Vacuum pressure- accuracy measurement 0.01[bar]
Reporting-
Process of weekly report: measurement file, responsibility Semion.
Monthly analysis - Responsibility Anan.