When doing ortohognal arrays testing, the process is like this:
Consider a function with 3 variables,each with 3 options.
- 3 pairs, each with 3*3 values = 27 parametric pairs.
- Each "function call" contains 3 pairs, i.e. in the optimal arrangement, I need only 27/3=9 test cases to cover all pair-wise combinations. I get that.
But there was an example with 75 binary options, which is 2775 pairs,each with 4 possible outcomes, i.e. 11100. In the ideal arrangement, one program call uses 2775 pairs, hence it seem 11100/2775= 4 test case to cover all pair wise conbimation. Is that even possible?


It's not possible. If we have $4$ rows in the covering array, then there are $2^4=16<75$ possible columns, so there are two identical columns, and for those two columns $10$ and $01$ are not tested.
Thus, there is no $4 \times 75$ binary orthogonal array. But this is unsurprising, orthogonal arrays are very special and fairly rare matrices. The parameters will usually have to be "just right" for one to exist.
The least number of rows where each pair is tested will have $\geq 7$ rows, since $2^6<75$ too (so we can apply the same argument).