Falcon 250 On-Gun Fume Extraction Kit
Australian workshops running manual MIG welding at 250 amps or below can set up on-gun fume extraction in a single purchase with the Falcon 250 Kit. The kit pairs FumeFree’s FF100 2.5HP portable vacuum with the 250-amp Falcon extraction torch, so fumes are captured at the arc instead of relying on general workshop ventilation. Everything needed to start welding the same day is included: the vacuum unit, the torch, adapter hardware for Tweco, Miller, and Lincoln feeders, and a full consumables set.
For workshops assessing their obligations under Safe Work Australia’s 2024 workplace exposure standard of 1 mg/m³ for welding fume, on-gun capture is one of the most direct ways to reduce a welder’s exposure at the source. See the full welding fume extraction range for Australia for other amperage classes and applications.
Specifications and Performance
- CO₂ shielding: 280 amps
- Mixed gases: 250 amps
- Duty cycle: 100%
- Gun weight: 2.95 lb (1.33kg)
- FF100 vacuum motor: 240V single-phase (AS/NZS 1668-compliant)
| 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 |
On-Gun Extraction at 250 Amps: How the Falcon 250 Works
Rather than pulling contaminated air out of the room after it has already spread, the Falcon 250 draws fume through a vacuum channel built into the torch itself. Suction starts right at the nozzle, at the point where the fume is generated, and carries it through the corrugated hose to the FF100 vacuum unit before it reaches the welder’s breathing zone.
This matters most in the situations where fume arms and overhead canopy hoods fall short: confined spaces such as tanks and ship hulls, large weldments where a welder is constantly moving and an arm cannot follow, and any high-mobility production environment where stopping to reposition external equipment isn’t practical.
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 managing exposure under Safe Work Australia’s WHS framework that want source capture without the cost of 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 rubberised 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 (2.4m) 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 used in Australian 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 (on-gun) 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
Every Falcon 250 Kit purchase includes direct access to FumeFree’s technical support team for adapter selection, airflow meter setup, and consumable sourcing. If your amperage regularly runs above this kit’s range, see the Falcon 400 Heavy-Duty Kit instead.
Complete Your Falcon 250 Setup
Keep your Falcon 250 running at full capacity with genuine FumeFree parts and accessories. Browse Accessories for Australian workshops for hose, couplers, and welding attachments, or the Spare Parts range for replacement handles, triggers, and cable assemblies. Both connect to any wire feeder or machine on the market using FumeFree’s full range of 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
Does the Falcon 250 meet Safe Work Australia's WHS welding fume standard?
Yes. The Falcon 250’s on-gun source capture design is built to help Australian workshops work toward Safe Work Australia’s exposure limit of 1 mg/m3 for welding fume, by extracting fumes at the point of generation rather than relying on general workshop ventilation alone. This limit is called the WES today. It becomes the WEL on 1 December 2026.
What comes in the Falcon 250 Kit?
The FF100 2.5HP portable vacuum, the 250-amp Falcon extraction torch, adapters for Tweco, Miller, and Lincoln feeders, and a starter set of consumables, ready to weld the day it arrives.
Where can I see FumeFree's full range for Australia?
Visit the FumeFree Australia homepage for the complete range of welding fume extraction systems available to Australian workshops.
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.