Falcon 400 Heavy-Duty Fume Extraction Kit
When a welding operation outgrows a lighter-duty extraction gun, the Falcon 400 Kit steps up to on-gun capture at up to 420 amps without losing the 100% duty cycle production welding depends on. FumeFree’s FF100 2.5HP portable vacuum pairs with the 400-amp Falcon extraction torch to pull fume away from the arc continuously, across a full shift, in shipbuilding yards, heavy fabrication shops, and production lines across Australia.
Higher amperage means higher fume volume, which is exactly where general workshop ventilation and repositioned fume arms start to fall behind. Capturing at the gun keeps pace with the welder instead. See the full welding fume extraction range for Australia for lighter-duty and specialty options.
Specifications and Performance
- CO₂ shielding: 420 amps
- Mixed gases: 400 amps
- Duty cycle: 100%
- Gun weight: 3.28 lb (1.49kg)
- 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 |
| FA4028505000 | Falcon 400 - Extractor Fume Gun - 400 amp - 16ft (5mtr) Air Cooled - 45° |
| 398120 | FF Hose to Torch Coupler (1.5" - 2") |
| 371300 | Airflow Meter (400 amp) Extractor |
| 3960205 | Tool for nozzle holder (400 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) |
| 3937041 | Nozzle 8XE Extractor .55 (14mm) special |
| 39327310 | 8XE (M8x1,5) Tip adapter 400AMP |
| 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 |
Pair it with the Falcon 400 – Kit ADVANCED!
To fully realize the performance benefits off the Falcon 400 – Kit, we recommend pairing it with our Falcon 400 – 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 completeFalcon 400 – Kit fume extraction product line easily integrates into your current welding operation.
As with all of our MIG guns, the Falcon 400 – Kit can be connected to any wire feeder/machine on the market by utilizing our various connector kits and adapters.
On-Gun Extraction at Up to 420 Amps: How the Falcon 400 Works
A dedicated vacuum channel runs the length of the gun cable, drawing fume through the nozzle assembly into the FF100 unit before it disperses into the welder’s breathing zone. At 400 to 420 amps, that matters more than it does at lower amperage: fume volume rises with amperage, and ambient ventilation or a repositioned fume arm can struggle to keep up, particularly on an open production floor where the welder is moving continuously.
The Falcon 400 Kit is well suited for:
- Heavy structural and plate welding at high amperage where fume output is elevated
- Production welding lines where 100% duty cycle is required and extraction cannot interrupt workflow
- Shipbuilding, heavy fabrication, and agricultural equipment manufacturing across Australia where large weldments make fume arm placement impractical
- Operations upgrading from a lower-amperage gun that can no longer keep pace with increased production parameters
The 50° neck bend and tapered fume nozzle position the extraction point to draw fumes away from the arc without pulling shielding gas off the weld pool. Maintaining the correct airflow balance at higher amperage is critical, which is why the kit includes a dedicated airflow meter calibrated for 400A extraction.
Falcon 400 Kit Features and Benefits
Improved Frontend Design for High-Amperage Capture
The frontend of the Falcon 400 has been designed to efficiently capture welding fumes at higher amperage. A shorter nozzle, 50° neck bend, and slim, tapered fume nozzle provide strong suction without interfering with shielding gas coverage at the weld pool.
Ergonomic Handle and Ball Joint Cable
The Falcon 400 handle is designed to balance comfort with the demands of a heavier cable assembly. The Rubberised grip and ball joint cable connection reduce strain during the directional changes that come with long production runs, keeping the welder in control across a full shift.
Spatter-Resistant Cable Cover
The Falcon 400 Kit ships with leather cable sheathing that protects the first 8 feet of corrugated extraction hose. Secured with velcro, the cover shields the hose from the spatter levels that come with higher-amperage welding, extending the service life of the extraction assembly.
Falcon 400 Wire Feeder Compatibility
The Falcon 400 Kit includes Tweco #4, Lincoln, and Miller adapter hardware so the gun connects directly to the wire feeders and power sources commonly used in heavy-duty MIG welding environments across Australia. Tweco #4 is the standard connection type for 400-amp class guns, and all three adapters are included in the kit along with matching quick-connect switch cable ends.
As with all of our MIG guns, the Falcon 400 can be connected to any wire feeder or machine on the market by utilising 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 400 Kit Right for Your Application?
The Falcon 400 Kit is the right choice once a lower-rated extraction gun can no longer match your process. It suits workshops where:
- Your process operates on CO₂ at up to 420 amps, or on mixed gas at up to 400 amps
- You weld on large structural components, heavy plate, or fabrications where repositioning a fume arm between passes is not practical
- You need a self-contained, portable system that requires no permanent ducting installation
- You require 100% duty cycle performance across a full production shift
Every Falcon 400 Kit purchase includes direct access to FumeFree’s technical support team for adapter selection, airflow balance, and consumable sourcing. If your process runs within a lighter range, the Falcon 250 On-Gun Kit may be the better fit.
Complete Your Falcon 400 Setup
Keep your Falcon 400 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.
| Part Number | DESCRIPTION | PACK QUANTITY |
| FF-B25-B01F0102 | FumeFree FF100 – 2.5HP Compact Welding Portable Vacuum w/17’ Hose | 1 |
| Part Number | DESCRIPTION | PACK QUANTITY |
| FA4028505000 | Falcon 400 – Extractor Fume Gun – 400 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 NumberDESCRIPTIONPACK QUANTITY
| 39302145 | Swanneck 45° | 1 |
| 3950205 | PEEK ring to fix nozzle holder (not shown) | 5 |
| 3950200 | Nozzle holder | 1 |
| 3950245 | Metal neck 45° | 1 |
| 391000 | Handle green/black complete with trigger | 1 |
| 3912009 | Trigger with spring | 1 |
| 391250 | Micro switch complete (not shown) | 1 |
| 381920 | Cable support set with ball-and-socket joint | 1 |
| 259465X8U | Cable assembly 16ft (5mtr) | 1 |
| 260018 | Leather-sheathing with velcro 6ft (2mtr) | 1 |
| 3402052 | Fume extraction hose 16ft (5mtr) | 1 |
| 398030 | Hose connection | 1 |
| 398100 | Housing (Y-shape) for fume extraction hose | 1 |
| 398015 | Connection ring | 1 |
| 398010 | Housing set for central connector | 1 |
| 30590012 | 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 |
| 371300 | Airflow meter Extractor | 1 |
- DURABILITY
- DEXTERITY
EN 420:2003
CE Category Category 2
EN 388:2016 3121X
Frequently Asked Questions
Does the Falcon 400 meet Safe Work Australia's WHS welding fume standard?
Yes. The Falcon 400’s on-gun source capture design is built to help Australian industrial and manufacturing workshops work toward Safe Work Australia’s exposure limit of 1 mg/m3 for welding fume, even at the higher fume volumes produced by 400-amp class welding. This limit is called WES today. It becomes the WEL on 1 December 2026.
Which Falcon kit is right if my process runs within 250 amps?
The Falcon 250 On-Gun Fume Extraction Kit is the lighter-duty option built on the same on-gun capture principle.
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 Falcon 400 fume extraction kit?
The Falcon 400 fume extraction kit is a complete source capture welding fume extraction system built for high-amperage MIG welding. It includes the FF100 2.5HP portable vacuum unit, the Falcon 400 400-amp air-cooled MIG fume extraction torch, all adapter hardware for Tweco, Miller, and Lincoln machines, and a full set of consumables. The kit ships ready to deploy without requiring additional component purchases.
What is the duty cycle of the Falcon 400?
The Falcon 400 is rated at 100% duty cycle at its rated amperage, making it suitable for continuous production welding without rest intervals. It is rated at 420 amps on CO₂ and 400 amps on mixed shielding gases.
Is the Falcon 400 compatible with my welding machine?
The Falcon 400 Kit includes Tweco #4, Miller, and Lincoln adapters along with quick-connect switch cable ends for each platform. As with all FumeFree MIG guns, the Falcon 400 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 400 support?
The Falcon 400 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 400 over the Falcon 250?
The Falcon 400 is designed for processes that operate above the Falcon 250’s rated range of 250 amps on mixed gas or 280 amps on CO₂. If your production parameters regularly exceed those thresholds, the Falcon 400 is the correct choice. If your process runs within the Falcon 250’s range and a lighter gun is preferred, see the Falcon 250 Kit.