Processes
- Aluminum MIG (GMAW)
- Aluminum pulsed MIG (GMAW-P)
- Aluminum synergic pulsed MIG
Miller Aluminum System Lookup
Miller AlumaFeed Aluminum Welding System
AlumaFeed synergic aluminum welding system support for XR-AlumaFeed SuitCase feeder, AlumaPower 450 MPa power source, XR push-pull guns, and MIGRunner package accessories.
Aluminum feeder system
Aluminum MIG (GMAW)Aluminum pulsed MIG (GMAW-P)Aluminum synergic pulsed MIGProfile Pulse aluminum welding
Spec Sheet Quick Specs
Heavy Industrial Applications
- Boat, ship, and yacht building
- Recreational vehicles
- Trucks and trailers
- Sign manufacturers
- Emergency vehicles
XR-AlumaFeed SuitCase
- Input power: 24 VAC, 5 A, 50/60 Hz
- Wire feed speed: 50-900 ipm (1.3-22.9 m/min.)
- Net weight: 31 lb. (14.1 kg)
AlumaPower 450 MPa
- Input power: 3-phase 230/460 V or 575 V, 60 Hz
- Output range: 10-38 V, 15-600 A
- Net weight: 122 lb. (55.3 kg)
MIGRunner Package Contents
The May 2026 data sheet lists stock number 951840 as the 230/460 V AlumaFeed MIGRunner package.
- XR-AlumaFeed SuitCase push-pull wire feeder
- 230/460 V AlumaPower 450 MPa power source
- 25 ft. air-cooled XR-Aluma-Pro gooseneck-style push-pull gun
- .035-inch and 3/64-inch contact tips, drive rolls, and liners for guns
- .035-inch and 3/64-inch drive rolls for the wire feeder, with 3/64-inch installed
- MIGRunner cart
- Industrial MIG 4/0 MIG kit with lug connectors
All AlumaFeed systems come set up out of the box to run 3/64-inch 5356 wire.
Order weld cables and other accessories separately.
Positive weld cable connection to the feeder requires the ring lug to be cut off and replaced with the Tweco-style connector supplied with the XR-AlumaFeed SuitCase feeder.
XR-AlumaFeed SuitCase Power Source Compatibility
| Power source | Pulse capable | Synergic pulsed MIG | Profile Pulse | Electronic inductance / SharpArc | Compatibility |
|---|---|---|---|---|---|
| AlumaPower 450 MPa | Yes (aluminum only) | Yes (aluminum only) | Yes | Yes | Optimized |
| XMT 450 MPa | Yes | Yes | Yes | Yes | Best |
| XMT 450 CC/CV | No | No | No | Yes | Better |
| XMT 400 | No | No | No | Yes | Better |
| XMT 650 | No | No | No | Yes | Better |
| Deltaweld (after KF790532) | No | No | No | No | Good |
The data sheet compatibility chart only lists current power sources; verify older systems with a Miller distributor before ordering cables or controls.
XR Push-Pull Gun Options
| Model | Welding current rating | Wire feed speed | Wire diameter capacity | Notes |
|---|---|---|---|---|
| XR-Aluma-Pro, air-cooled | 300 A at 100% duty cycle | 70-900 ipm | .030-1/16 in. aluminum wire | Requires gun wire kit 230708 to run 1/16-inch wire. |
| XR-Aluma-Pro, water-cooled | 400 A at 100% duty cycle | 70-900 ipm | .030-1/16 in. aluminum wire | Requires gun wire kit 230708 to run 1/16-inch wire. |
| XR-Pistol-Pro, air-cooled | 200 A at 100% duty cycle; 250 A at 60% duty cycle | 70-900 ipm | .030-1/16 in. aluminum wire | Pistol-grip push-pull gun option listed as compatible with AlumaFeed. |
| XR-Pistol-Pro, water-cooled | 400 A at 100% duty cycle | 70-900 ipm | .030-1/16 in. aluminum wire | Water-cooled pistol-grip push-pull gun option. |
Typical Installation Path
- AlumaPower 450 MPa or another compatible power supply connects to the XR-AlumaFeed SuitCase wire feeder.
- The 10 ft. 24 VAC contactor cord is supplied with the feeder.
- The feeder connects to an XR-Aluma-Pro or XR-Pistol-Pro push-pull gun.
- Cords and cables are supplied unless noted otherwise in the data sheet; use the Owner's Manual for complete installation instructions.
Compatibility Snapshot
- Miller DC/34.0 lists AlumaFeed as a synergic aluminum welding system for aluminum MIG, aluminum pulsed MIG, and aluminum synergic pulsed MIG.
- The system combines the XR-AlumaFeed SuitCase push-pull wire feeder with the AlumaPower 450 MPa power source and XR push-pull guns.
- The package includes consumables for .035-inch and 3/64-inch wire; 1/16-inch wire requires gun wire kit 230708 and drive roll kit 268850.
- Use XR push-pull gun and feeder drive-roll requirements before ordering aluminum consumables.
Machine Specs
| Model | Stock numbers | Output / speed range | Rated output | Input power | Weight |
|---|---|---|---|---|---|
| XR-AlumaFeed SuitCase Feeder | 301567 | 50-900 ipm wire feed speed | 400 A at 100% duty cycle; system duty cycle is limited to gun rating | 24 VAC, 5 A, 50/60 Hz | 31 lb. |
| AlumaPower 450 MPa | 907483, 907484 | 15-600 A / 10-38 V | 450 A at 36.5 VDC, 100% duty cycle | 230/460 V or 575 V | 122 lb. |
AlumaFeed System Packages
| Stock number | Catalog item | Included gun / cooling path | Manufacturer UPC check | Notes |
|---|---|---|---|---|
| 951842 | AlumaFeed 230/460 V stationary package | 25 ft. water-cooled XR-Aluma-Pro push-pull MIG gun | Not found in uploaded Miller UPC file | Includes Coolmate 3; no cart listed in the catalog row. |
| 951840 | AlumaFeed 230/460 V MIGRunner package PKG,ALUMAFEED 450 MIGRUNNER W/25 FT XR ALUMA-PRO A |
25 ft. air-cooled XR-Aluma-Pro push-pull MIG gun | 715959683494 | Includes industrial MIG 4/0 kit with lug connectors and MIGRunner cart. |
| 951867 | AlumaFeed 230/460 V MIGRunner package | 25 ft. water-cooled XR-Aluma-Pro push-pull MIG gun | Not found in uploaded Miller UPC file | Includes industrial MIG 4/0 kit with lug connectors, Coolmate 3, and MIGRunner cart. |
Compatible Power Sources
AlumaPower 450 MPa
Included power source in the AlumaFeed system packages.
Open support pageXMT 450 MPa
Related MPa aluminum welding power-source path from the Miller catalog.
Open support pageCompatible Guns / Torches
XR-Aluma-Pro
Gooseneck-style push-pull gun listed with the AlumaFeed system in 15-, 25-, and 35-foot air-cooled or water-cooled versions.
Open support pageXR-Pistol-Pro
Pistol-grip push-pull gun listed as compatible with the AlumaFeed synergic aluminum welding system.
Open support pageMiller MIG Drive Rolls
Use for feeder and gun drive-roll verification before ordering aluminum consumables.
Open support pageAccessories To Check
| Part number | Accessory | Use | Manufacturer UPC check | Buy / support |
|---|---|---|---|---|
| 301568 | XR-Aluma-Pro gun, 15 ft, air-cooled XR-A ALUMA-PRO 15FT. |
Gooseneck-style push-pull gun option listed in the DC/34.0 data sheet. | 688515371114 | Buy link unavailable. |
| 301569 | XR-Aluma-Pro gun, 25 ft, air-cooled XR-A ALUMA-PRO 25FT. |
Gooseneck-style push-pull gun option listed in the DC/34.0 data sheet. | 715959682985 | Buy link unavailable. |
| 301570 | XR-Aluma-Pro gun, 35 ft, air-cooled XR-A ALUMA-PRO 35FT. |
Gooseneck-style push-pull gun option listed in the DC/34.0 data sheet. | 688515371138 | Buy link unavailable. |
| 301571 | XR-Aluma-Pro gun, 15 ft, water-cooled XR-ALUMA-PRO 15W |
Water-cooled gooseneck-style push-pull gun option. | 715959683005 | Buy link unavailable. |
| 301572 | XR-Aluma-Pro gun, 25 ft, water-cooled XR-ALUMA-PRO 25W |
Water-cooled gooseneck-style push-pull gun option. | 688515371152 | Buy link unavailable. |
| 301573 | XR-Aluma-Pro gun, 35 ft, water-cooled XR-ALUMA-PRO 35W |
Water-cooled gooseneck-style push-pull gun option. | 688515371169 | Buy link unavailable. |
| 300782 | XR-Pistol-Pro gun, 15 ft, air-cooled XR-15A PISTOL PRO |
Pistol-grip push-pull gun option listed in the DC/34.0 data sheet. | 715959556651 | Buy link unavailable. |
| 300783 | XR-Pistol-Pro gun, 25 ft, air-cooled XR-25A PISTOL PRO |
Pistol-grip push-pull gun option listed in the DC/34.0 data sheet. | 715959556668 | Buy link unavailable. |
| 300784 | XR-Pistol-Pro gun, 35 ft, air-cooled XR-35A PISTOL PRO |
Pistol-grip push-pull gun option listed in the DC/34.0 data sheet. | 715959556675 | Buy link unavailable. |
| 300786 | XR-Pistol-Pro gun, 15 ft, water-cooled XR-15W PISTOL PRO |
Water-cooled pistol-grip push-pull gun option. | 715959556699 | Buy link unavailable. |
| 300787 | XR-Pistol-Pro gun, 25 ft, water-cooled XR-25W PISTOL PRO |
Water-cooled pistol-grip push-pull gun option. | 715959556705 | Buy link unavailable. |
| 300788 | XR-Pistol-Pro gun, 35 ft, water-cooled XR-35W PISTOL PRO |
Water-cooled pistol-grip push-pull gun option. | 715959556712 | Buy link unavailable. |
| M1681 | Replacement cable cover, 15 ft KIT, CABLE JACKET, 15 FT |
Protects gun hose and cable assembly; full-length hook-and-loop closure. | 715959685146 | Buy link unavailable. |
| M1682 | Replacement cable cover, 25 ft KIT, CABLE JACKET, 25 FT |
Protects gun hose and cable assembly; full-length hook-and-loop closure. | 715959685153 | Buy link unavailable. |
| M1683 | Replacement cable cover, 35 ft KIT, CABLE JACKET, 35 FT |
Protects gun hose and cable assembly; full-length hook-and-loop closure. | 715959685160 | Buy link unavailable. |
| 231519 | Short air-cooled head tube assembly KIT,HEAD TUBE ASSY AIR AP/PP 60DEG 4IN |
60-degree, 4-inch standard head tube with liner. | 715959378338 | Buy link unavailable. |
| 231518 | Long air-cooled head tube assembly KIT,HEAD TUBE ASSY AIR (A) AP/PP 60DEG 6IN |
60-degree, 6-inch optional head tube with liner. | 715959378345 | Buy link unavailable. |
| 233998 | Phosphorous bronze liner, short head tube LINER,PHOS BRONZE .030-1/16 WIRE (SHORT ALUMA-PRO) |
For use with hardwire liner kit 198377 in XR-Aluma-Pro gun. | 715959387156 | Buy link unavailable. |
| 233999 | Phosphorous bronze liner, long head tube LINER,PHOS BRONZE .030-1/16 WIRE (LONG ALUMA-PRO) |
For use with hardwire liner kit 198377 in XR-Aluma-Pro gun. | 715959387187 | Buy link unavailable. |
| 198377 | Hardwire liner kit for steel and stainless KIT,HARDWIRE LINER 30FT FOR STEEL&STAINLESS |
Used with phosphorous bronze liners when configured for hardwire. | 715959244718 | Buy link unavailable. |
| 195445 | MIGRunner cart CART,MIGRUNNER (INVERTER) |
Small-footprint cart with low cylinder rack, listed with the AlumaFeed system. | 715959288323 | Buy link unavailable. |
| 042934 | Universal carrying cart and cylinder rack UNIVERSAL CARRYING CART AND CYL RACK |
Holds power source and gas cylinder up to 56 inches high, 6-9 inches in diameter. | 715959006149 | Buy link unavailable. |
| 043809 | Coolant COOLANT,ALUMINUM PROTECTING SOLD IN MULTI OF 4 |
Coolant listed in the DC/34.0 data sheet; sold in cases of four one-gallon recyclable plastic bottles. | 715959279512 | Buy link unavailable. |
| 300390 | Industrial MIG 4/0 kit with lug connectors KIT,INDUSTRIAL MIG 4/0 |
Includes flowmeter regulator, gas hose, 4/0 feeder weld cable, and work cable with 600-amp C-clamp. | 715959384742 | Buy link unavailable. |
| 301306 | Flowmeter kit ARCREACH FEEDER, GAS FLOW METER, KIT |
Includes flowmeter and components required for mounting to the back of the XR-AlumaFeed SuitCase feeder. | 715959623483 | Buy link unavailable. |
| 301592 | SuitCase mounting bracket XR-ALUMAFEED SUITCASE MOUNTING BRACKET |
For mounting the XR-AlumaFeed SuitCase to the MIGRunner cart or another customer-determined mounting location. | 715959683265 | Buy link unavailable. |
| 247831025 | 11-conductor extension cable, 25 ft CABLE,EXTENSION 24 VAC 14 PIN 11C 25 FT |
Supports contactor control and remote voltage control for XR-AlumaFeed SuitCase feeder. | 715959560436 | Buy link unavailable. |
| 247831050 | 11-conductor extension cable, 50 ft CABLE,EXTENSION 24 VAC 14 PIN 11C 50 FT |
Supports contactor control and remote voltage control for XR-AlumaFeed SuitCase feeder. | 715959560443 | Buy link unavailable. |
| 247831080 | 11-conductor extension cable, 80 ft CABLE,EXTENSION 24 VAC 14 PIN 11C 80 FT |
Supports contactor control and remote voltage control for XR-AlumaFeed SuitCase feeder. | 715959561525 | Buy link unavailable. |
| 230708 | 1/16-inch gun wire kit KIT,IDLER ROLL 1/16(.062) (XR-ALUMA-PRO GUN) |
Required with 1/16-inch drive roll kit 268850 to run 1/16-inch wire. | 715959375467 | Buy link unavailable. |
| 268850 | 1/16-inch control box drive roll kit KIT,DRIVE ROLL POLISHED XR 1/16 AL |
Required with 1/16-inch wire kit 230708 to run 1/16-inch wire on XR-AlumaFeed SuitCase. | 715959614122 | Buy link unavailable. |
Related Lookup Pages
i er wire feeder suppor
Related Miller wire feeder support path.
Open support pageMiller 74 MPa Plus Bench Feeders
S-74 MPa Plus and D-74 MPa Plus feeder path for heavy industrial MIG, flux-cored, pulsed MIG, and aluminum push-pull systems.
Open support pagei er xr a u a pro
Related Miller wire feeder support path.
Open support pagei er xr pis o pro
Related Miller wire feeder support path.
Open support pageMiller MIG Drive Rolls
Drive roll lookup for Miller MIG and feeder setups.
Open support pageMiller Catalog Accessories
These accessories are placed here only when the Miller catalog names this machine, torch, feeder, or family path. Verify plug style, voltage, package, and serial-specific details before ordering.
| Part | Accessory | Catalog fitment | Source / path |
|---|---|---|---|
| 195461 | Coolant Flow Switch | Water-cooled guns; verifies coolant flow before welding. | Catalog p. 121 Open support path |
| 043007 | Coolmate 3 | 3-gallon cooler for water-cooled torches up to 500 amps. | Catalog p. 123 Open support path |
| 043008 | Coolmate 3 | 240 V 3-gallon cooler for water-cooled torches up to 500 amps. | Catalog p. 123 Open support path |
| 042288 | Coolmate 4 | Industrial 4-gallon cooler for water-cooled torches up to 600 amps. | Catalog p. 123 Open support path |
| 043810 | Low-Conductivity Coolant | For TIG and MIG water-cooled systems where aluminum is not in the coolant path/circuit. | Catalog p. 123 Open support path |
Need More Help?
Wire Feed Problems
Use troubleshooting only after confirming the feeder model, power-source path, gun, wire size, and drive rolls.
Find My Part
Search by feeder stock number, gun family, drive roll, or power-source model when the setup is not clear.
Source: Miller Electric 2026 Full-Line Catalog, catalog pages 9, 28, 122, 123, 125, 130. Additional source: Miller AlumaFeed MIG Welding System for Aluminum Welding data sheet, issued May 2026, Index No. DC/34.0. Manufacturer UPC checks come from the uploaded Miller product/UPC file and are shown for verification only. Purchase placeholders are shown where no support page exists.
Approved Buy Links
OEM-backed Amazon Links
1/16-inch control box drive roll kit KIT,DRIVE ROLL POLISHED XR 1/16 AL
Parts: 268850, 715959614122
View on Amazon
11-Conductor Cable
Parts: 247831025, 715959560436
View on Amazon
11-Conductor Cable
Parts: 247831050, 715959560443
View on Amazon
11-Conductor Cable
Parts: 247831080, 715959561525
View on Amazon
Coolant Flow Switch
Part: 195461
View on Amazon
Coolmate 3 COOLMATE 3 115V,CE
Part: 715959177351
View on Amazon
Coolmate 4
Part: 42288
View on Amazon
Gun wire kit for 1/16 in. wire KIT,IDLER ROLL 1/16(.062) (XR-ALUMA-PRO GUN)
Part: 715959375467
View on Amazon
Industrial MIG 4/0 kit with lug connectors KIT,INDUSTRIAL MIG 4/0
Parts: 300390, 715959384742
View on Amazon