Falcon 250 Fume Extraction Kit
The Falcon 250 fume extraction kit is a complete, ready-to-weld source capture system. It pairs the FF100 2.5HP compact portable vacuum with the 250-amp Falcon extraction torch, plus all the adapter hardware and consumables your welders need to get started.
The complete kit includes the FF100 portable vacuum, the Falcon 250 extraction torch, coupler and adapter hardware for Tweco, Miller, and Lincoln machines, and a full set of consumables to begin welding immediately.
Specifications and Performance
- CO₂ shielding: 280 amps
- Mixed gases: 250 amps
- Duty cycle: 100%
- Gun weight: 2.95 lb
| Part Number | Description |
| FF-B25-B01F0102 | FumeFree FF100 - 2.5HP Compact Welding Portable Vacuum w/17' Hose |
| FA1000505000 | Falcon 250 - Extractor Fume Gun - 250 amp - 16ft (5mtr) Air Cooled - 45° |
| 398120 | FF Hose to Torch Coupler (1.5" - 2") |
| 371350 | Airflow Meter (250 amp) Extractor |
| 3960005 | Tool for nozzle holder (250 amp) |
| 3059100 | Tweco #4 Adapter |
| 3059200S | Lincoln Adapter complete with gas hose |
| 3059150 | Miller Adapter |
| 349130 | Tweco Switch cable end (Quick connect) |
| 349120 | Miller Switch cable end (Quick connect) |
| 349110 | Lincoln Switch cable end (Quick connect) |
| 3937001 | Nozzle 8XE MINI Extractor .55 (14mm) special |
| 39327110 | 8XE (M8x1,5) Tip adapter MINI |
| 3990091 | Contact tip 8XE (M8x1,5) - .035 (0,9) CuCrZr |
| 3990121 | Contact tip 8XE (M8x1,5) - .045 (1,2) CuCrZr |
| 302555-USA | Plastic coated USA liner red 16ft (5mtr) - for .035 to .045 wire |
How Does the Falcon 250 Extract Welding Fumes?
The Falcon 250 uses high-vacuum source capture. A vacuum channel built into the extraction torch draws welding fumes directly from the nozzle area, at the point of generation, and routes them through the corrugated hose to the FF100 vacuum unit.
This is a fundamentally different approach from fume arms and canopy hoods, which capture fumes only after they have already risen into the welder’s breathing zone. Because the Falcon 250 captures at the gun, it requires significantly less airflow volume and does not need to be repositioned as the welder moves.
The Falcon 250 Kit is particularly effective for:
- Welders working on large weldments where a fume arm cannot follow the arc
- Confined space welding such as tanks, ship hulls, and structural cavities where overhead extraction is not practical
- High-mobility applications that require continuous extraction without interrupting workflow
- Facilities that need OSHA-compliant source capture without investing in permanent ducting infrastructure
The tapered fume nozzle and 45° neck position the extraction point correctly relative to the weld pool. Fumes are drawn away without disturbing the shielding gas flow, which is the key engineering consideration that prevents porosity.
Falcon 250 Kit Features and Benefits
Redesigned Frontend for Maximum Capture
The frontend of the Falcon 250 has been redesigned from previous models to more efficiently capture welding fumes. A shorter nozzle, 45° neck bend, and slim, tapered fume nozzle provide more suction without interfering with shielding gas.
Ergonomic, Lightweight Handle and Ball Joint
The Falcon 250 handle is our lightest fume extraction gun handle and is designed to comfortably sit in the welder's hands. The rubberized grip and ball joint cable connection provide added comfort and control while welding.
Protective
Cable Cover
When you purchase the Falcon 250 Kit, it comes standard with a protective cable cover for the first 8 feet of corrugated hose. This cover is resistant to spatter and prevents the corrugated hose from snagging in the work area.
Falcon 250 Wire Feeder Compatibility
The Falcon 250 Kit includes adapter hardware for the three most common wire feeder platforms in North American fabrication shops:
- Tweco
- Lincoln
- Miller
All adapters and quick-connect switch cable ends are included in the kit. As with all of our MIG guns, the Falcon 250 can be connected to any wire feeder or machine on the market by utilizing our various connector kits and adapters. Contact FumeFree to confirm the correct adapter for your machine if it is not listed above.
Is the Falcon 250 Kit Right for Your Application?
The Falcon 250 Kit is designed for manual MIG welding operations where source capture is required and a portable, self-contained solution is preferred over fixed ducting infrastructure. The Falcon 250 Kit is the right choice when:
- Your process uses CO₂ or mixed gas shielding at 250 to 280 amps or below
- You need a portable, single-station solution that moves between workstations
- You require 100% duty cycle performance for continuous production welding
When you purchase a Falcon 250 Kit, you get direct access to FumeFree’s technical support team. Whether you need help selecting the right adapter for your wire feeder, dialing in the airflow meter, or sourcing replacement consumables, we are available to help you get the most out of your system.
Pair It with the Falcon 250 Kit ADVANCED
To fully realize the performance benefits of the Falcon 250 Kit, we recommend pairing it with our Falcon 250 Kit ADVANCED fume extraction vacuum systems.
Through optimum coordination between a high-vacuum system and a high-vacuum welding gun, we ensure highly efficient extraction directly at the source with a clear view of the arc. Our complete Falcon 250 fume extraction product line easily integrates into your current welding operation.
As with all of our MIG guns, the Falcon 250 can be connected to any wire feeder or machine on the market by utilizing our various connector kits and adapters.
Catalog & Ordering Chart
| Part Number | DESCRIPTION | PACK QUANTITY |
| FF-B25-B01F0102 | FumeFree FF100 – 2.5HP Compact Welding Portable Vacuum w/17’ Hose | 1 |
Catalog & Ordering Chart
| Part Number | DESCRIPTION | PACK QUANTITY |
| FA1000505000 | Falcon 250 – Extractor Fume Gun – 250 amp – 16ft (5mtr) Air Cooled – 45° | 1 |
| Part Number | DESCRIPTION | PACK QUANTITY |
| 320300 | Ceramic dry film spray (400ml) | 1 |
| FFIL-050-126P0000 | 8″ x 12″ Polyester Cartridge Filter | 1 |
| FHOS-05B-35015317 | 1-1/2″ x 17′ Black Hose with 1-1/2″ Cuffs | 1 |
| FHOS-PLA-90121000 | 1-1/2″ Hose Coupler (Grey) | 1 |
| FHOS-PLA-93021000 | 1-1/2 Thread To Thread (Extension) Hose Coupler (Grey) | 1 |
| FSYS-030-57700000 | Welding Attachment – Wide Suction Head with 1.5″ Hose Connection | 1 |
| FSYS-030-57900000 | Welding Attachment – Thin & Wide Suction Head with 1.5″ Hose Connection | 1 |
| FSYS-030-58000000 | Welding Attachment – Round Suction Head with 1.5″ Hose Connection | 1 |
| FSYS-030-58100000 | Welding Attachment – Surface Level Head with 1.5″ Hose Connection | 1 |
| Part Number | DESCRIPTION | PACK QUANTITY |
| 39301045 | Swanneck 45° | 1 |
| 3950005 | PEEK ring to fix nozzle holder (not shown) | 5 |
| 3950000 | Nozzle holder | 1 |
| 3950045 | Metal neck 45° | 1 |
| 3950500 | Adapter to fit MINI neck | 1 |
| 391000 | Handle green/black complete with trigger | 1 |
| 3912009 | Trigger with spring | 1 |
| 391250 | Micro switch complete (not shown) | 1 |
| 381900 | Cable support set with ball-and-socket joint | 1 |
| 259265X8 | Cable assembly 16ft (5mtr) | 1 |
| 260019 | Leather-sheathing with velcro 6ft (2mtr) | 1 |
| 340305 | Fume extraction hose 16ft (5mtr) | 1 |
| 398031 | Hose connection | 1 |
| 398100 | Housing (Y-shape) for fume extraction hose | 1 |
| 398015 | Connection ring | 1 |
| 398010 | Housing set for central connector | 1 |
| 3059001 | Central connector | 1 |
| 398200 | Adaptor nut | 1 |
| 3059100 | Tweco tail | 1 |
| 3059200S | Lincoln tail complete with gas hose | 1 |
| 3059150 | Miller tail | 1 |
| 349200 | Switch cable 45cm (Quick connect) | 1 |
| 306545 | Locking clip (Quick connect) | 5 |
| 349130 | Tweco switch cable end (Quick connect) | 1 |
| 349120 | Miller switch cable end (Quick connect) | 1 |
| 349110 | Lincoln swith cable end (Quick connect) | 1 |
| 406050 | Gasflow meter | 1 |
| 371208 | Tool set (brush and multitool) | 1 |
| 371350 | Airflow meter MINI Extractor | 1 |
Frequently Asked Questions
What is the Falcon 250 fume extraction kit?
The Falcon 250 fume extraction kit is a complete source capture welding fume extraction system. It includes the FF100 2.5HP portable vacuum unit, the Falcon 250 250-amp air-cooled MIG fume extraction torch, all adapter hardware for Tweco, Miller, and Lincoln machines, and a full set of consumables. The kit is designed for manual MIG welding operations that require fume extraction directly at the source.
What is the duty cycle of the Falcon 250?
The Falcon 250 is rated at 100% duty cycle, meaning it operates continuously without rest intervals. It is rated at 280 amps on CO₂ and 250 amps on mixed shielding gases.
Is the Falcon 250 compatible with my welding machine?
The Falcon 250 Kit includes adapters and switch cable ends for Tweco, Miller, and Lincoln wire feeders. As with all FumeFree MIG guns, the Falcon 250 can be connected to any wire feeder or machine on the market using FumeFree’s full range of connector kits and adapters. Contact us if your machine brand is not listed above.
What wire sizes does the Falcon 250 support?
The Falcon 250 Kit ships with CuCrZr contact tips and a plastic-coated liner for .035″ (0.9 mm) and .045″ (1.2 mm) wire. The included liner runs the full 16-foot (5-metre) cable length at both wire sizes. Please contact us for consumable specifications outside this range.
When should I choose the Falcon 250 over the Falcon 400?
The Falcon 250 is designed for welding applications up to 250 amps on mixed gas or 280 amps on CO₂. If your process regularly operates above those thresholds, the Falcon 400 is the appropriate choice. Both kits are available with compatible portable vacuum units and full adapter coverage. See the Falcon 400 Kit.