Plant-wide upgrade
Upgrading a plant full of Dimensionair gages
Replace dozens or hundreds of dial air gages with digital Air Gage Pro stations, keep every plug, ring and master, and roll out one line at a time.
Many plants run dozens, sometimes hundreds, of Dimensionair and other single-master dial gages. The tooling is durable and operators trust it; what ages is the readout. Replacing readouts station by station keeps every plug, ring and master you own, and turns each gage into a digital, data-ready station.
Why plants upgrade the whole fleet
- Consistent readings. A color-coded digital value removes the judgment in reading a pointer between graduations.
- Data for SPC and traceability. Every station can export readings over USB or RS232 instead of relying on handwritten logs.
- Fewer models to support. One Air Gage Pro M5-L covers D-2500 through D-8000, and one M5-H covers D-10000 through D-32000. See air gage amplification explained.
- Faster changeovers. Setups load by QR code, and programs are password-protected.
- No retooling. Existing single-master tooling and masters stay in service.
A rollout that doesn't disrupt production
- Count and match. List each station's readout model and tooling. Send us the list, even a phone photo of a spreadsheet, and we'll match every station to an M5-L, M5-H or M5 Dual.
- Pilot. Start with one or two stations on a critical part. Run them side by side with a dial and compare results, or run a gage R&R.
- Roll out by cell or line. Changeover takes under 2 minutes per station, so a line can switch during a break.
- Connect the data. When you're ready, send readings to SPC, Excel or your MES over USB or RS232.
Match your stations
| Readouts in your plant | Replace with |
|---|---|
| Dimensionair D-2500, D-4000, D-5000, D-8000; Federal EAG-31xxx, EAG-32xxx; Western Gage Series 60 | Air Gage Pro M5-L |
| Dimensionair D-10000, D-16000, D-20000, D-32000; Federal EAG-33xxx, EAG-34xxx; Western Gage Series 70 | Air Gage Pro M5-H |
| Two-master readouts, any brand | Air Gage Pro M5 Dual |
Two stations on one bench? A 2-input unit runs both from one screen. See the Dimensionair replacement guide for details and the three-step changeover.
Dimensionair, Mahr, MahrFederal, Federal, Millimar and Western Gage are trademarks of their respective owners, used only to identify compatible equipment. Air Gaging LLC is not affiliated with or endorsed by them.
Request fleet pricing
Tell us roughly how many gages and which models. We'll match every station and reply within one business day.
Questions
Do you offer volume pricing?
Yes. Pricing for multiple units is quoted on request. Tell us how many stations and which models, and we'll send a formal quote.
Can we try one before converting a line?
Yes. Most plants start with a pilot on one or two stations and compare against the existing dial or with a gage R&R.
Do we need new tooling or masters?
No. The Air Gage Pro connects to your existing single-master plugs, rings and masters.
How long does each station take to change over?
Typically under 2 minutes: remove the old readout, connect the tooling, air and power, and master.
We have a mix of low- and high-amp gages. Is that a problem?
No. Low-amp stations take the M5-L and high-amp stations take the M5-H. We'll match every station from your list.
Can readings go to our SPC or MES system?
Yes. Each unit exports over USB (Excel/CSV, keyboard emulation) and RS232 (ASCII or Modbus RTU).