Issued April 2016 • Index No. DC/34.0 MIG Welding System for Aluminum Welding Synergic Aluminum Welding System Heavy Industrial Applications Quick Specs Boat, ship and yacht building Recreational vehicles Trucks and trailer Sign manufacturers Emergency vehicles Processes Aluminum MIG (GMAW) Aluminum pulsed MIG (GMAW-P) Aluminum synergic pulsed MIG XR-AlumaFeed Input Power AlumaPower 350 MPa and 450 MPa Input Power 350: Requires 3- or 1-phase power, 208–575 V, 50/60 Hz 450: Requires 3-phase power, 230/460 V, 60 Hz Wire Feed Speed 50–900 ipm (1.3–22.9 m/min.) The XR-AlumaFeed™ and AlumaPower™ 350 MPa or 450 MPa combine for a synergic system that simplifies and improves MIG and pulsed MIG welding applications for aluminum welding. Ultra portable and versatile. The slim ergonomic design of the XR-Aluma-Pro torch allows access into the tightest of quarters. Coupled with the XR-AlumaFeed feeder and the AlumaPower 350 MPa or 450 MPa synergic power supply, it has the features for all of your aluminum fabrication needs. Comes complete with: XR-AlumaFeed push-pull wire feeder AlumaPower 350 MPa OR 450 MPa power source XR-Aluma-Pro™ OR XR™-Pistol push-pull welding gun .035- and 3/64-inch (0.9 and 1.2 mm) contact tips, drive roll and liners for guns .035- and 3/64-inch (0.9 and 1.2 mm) drive rolls for wire feeder, 3/64-inch installed Note: All AlumaFeed systems come set up out of the box to run 3/64-inch (1.2 mm) 5356 wire. Order weld cables and other accessories separately. Synergic pulsed welding mode offers the simplicity of single-knob control. The machine will select the correct pulse power based on the wire feed speed (WFS) set by the operator. Synchronized, true push-pull wire feed system. Slave/torque motor ensures smooth, consistent feeding and improved arc performance, while reducing the problems normally associated with feeding aluminum. ™ Profile Pulse. Achieve “stacked dime” weld bead appearance without back-stepping. See page 2 for more information. Parameter and system locks provide three levels of protection to prevent accidental modification of welding parameters or manipulation of setup menu items. AlumaFeed synergic aluminum welding system with AlumaPower 450 MPa and XR-Aluma-Pro gun shown. AlumaFeed synergic aluminum welding system also available with XR-Pistol gun. Power source/wire feeder are warranted for three years, parts and labor. Original main power rectifier parts are warranted for five years. Gun warranted for one year, parts and labor. Equipment Sales US and Canada MillerWelds.com An ITW Welding Company 1635 West Spencer Street P.O. Box 1079 Appleton, WI 54912-1079 USA Phone: 866-931-9730 FAX: 800-637-2315 International Phone: 920-735-4554 In

AlumaFeed Synergic Aluminum Welding System Features ™ ™ Profile Pulse. Achieve “stacked dime” weld bead appearance without back-stepping. Profile Pulse frequency can be changed to increase or decrease the spacing between the ripple pattern to achieve the desired weld appearance. Flowmeter Drive Assembly Weld Cross Section Synergic “One-Knob” Control Begin and end welds with ease and confidence. Hot Start ™ eliminates incomplete fusion at the beginning of a weld, a common issue with aluminum welding. Crater gradually decreases weld current at the end of a weld to eliminate crater defects. Adjustable...

XR-AlumaFeed Wire Feeder ™ Gun calibration allows control box to sync with the welding gun for precise wire feed control that is critical for reducing weld defects and providing flawless synergic operation. Trigger schedule select (SCHD) allows the operator to select the alternative schedule by quickly tapping the gun trigger when not welding. Useful when switching between two welding parameters is needed. Advanced trigger provides “trigger interlock” capability and the ability to control the amount of time spent in the arc start and arc crater steps. Setup guide on inner panel of feeder has...

XR-Aluma-Pro Specifications (Subject to change without notice.) ™ Welding Current Rating Wire Feed Speed Wire Diameter Capacity XR-Aluma-Pro™ (air-cooled) XR-Aluma-Pro™ (water-cooled) 70 – 900 ipm (1.8 – 23 m/min.) dependent on control box or Millermatic® used .030 –1/16 in. (0.8 –1.6 mm) aluminum wire Wire kit 230708 required to run 1/16 in. (1.6 mm) wire XR-Aluma-Pro Parts Breakdown Air-Cooled XR-Aluma-Pro 4 1. Air-Cooled Assembly Short Head Tube, 4 in. 231519 Long Head Tube, 6 in. 231518* 2. Head Tube Liner (see chart below) 3. Head Tube O-Rings 230969 4. Lock Nut 227168 5. Insulator Ring...

XR -Pistol Specifications (Subject to change without notice.) ™ Welding Current Rating XR-Pistol (air-cooled) 200 A at 100% duty cycle 250 A at 60% duty cycle XR-Pistol (water-cooled) Wire Diameter Capacity Wire Feed Speed Gun only: 2.2 lb. (1 kg) 15 ft. gun with cable: 13 lb. (5.9 kg) 30 ft. gun with cable: 21 lb. (9.5 kg) Gun only: 2.4 lb. (1.1 kg) 15 ft. gun with cable: 14 lb. (6.4 kg) 30 ft. gun with cable: 21.5 lb. (9.8 kg) Air-Cooled Assembly Water-Cooled Assembly* Head Tube Liner O-Ring .614 ID Head Tube (Air-cooled) Head Tube (Water-cooled)* Head Tube Pistol Insulator Outer Insulating...

AlumaPower 350/450 MPa Power Source ™ Easy setup for MIG and pulsed MIG applications. Auto-Line™ power management technology on 350 model allows for any input voltage hook-up (208–575 V) with no manual linking. Ideal solution for dirty or unreliable input power. (450 model is manual link.) Additional Features Line voltage compensation keeps welding output constant even if input power varies by +/-10 percent. 350 models further expand line voltage compensation to an amazing +37%/-59 percent when operating on 460 V. Fan-On-Demand™ cooling system operates only when needed, reducing noise, energy...

AlumaPower Genuine Miller Accessories ® Industrial MIG 4/0 Kit with Dinse Connectors 300405 For AlumaPower 350 MPa power source. Includes flowmeter regulator with 10-foot (3 m) gas hose, 10-foot (3 m) 4/0 feeder weld cable with Dinse-style connector on one end and a lug on the other, 15-foot (4.6 m) work cable with Dinse-style connector on one end and 600-amp C-clamp on the other. Industrial MIG 4/0 Kit 300390 For AlumaPower 450 MPa power source. Includes the same as the kit above, except weld and work cables have lugs instead of Dinse-style connectors. Remote Control Extension Kits 242205025...