Falcon 400 Fume Extraction Kit
The Falcon 400 fume extraction kit is a high-amperage, source capture system built for demanding production welding environments. It combines the FF100 2.5HP compact portable vacuum with the 400-amp Falcon extraction torch, delivering 100% duty cycle fume control at weld parameters that exceed the range of lighter-duty extraction guns.
The complete kit includes the FF100 portable vacuum, the Falcon 400 extraction torch, coupler and adapter hardware for Tweco, Miller, and Lincoln machines, and a full set of consumables rated for .035″ and .045″ wire.
Specifications and Performance
The Falcon 400 Kit is rated for:
- CO₂ shielding: 420 amps
- Mixed gases: 400 amps
- Duty cycle: 100%
- Gun weight: 3.28 lb
| 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 |
How Does the Falcon 400 Extract Welding Fumes?
The Falcon 400 uses high-vacuum source capture to remove welding fumes at the point of generation. A dedicated vacuum channel runs through the gun cable and draws fumes through the nozzle assembly directly into the FF100 vacuum unit, before they can disperse into the welder’s breathing zone.
At 400 to 420 amps, welding operations produce fume volumes that ambient ventilation and fume arms struggle to control effectively, particularly in open production environments or when the welder is moving continuously across a weldment. Because the Falcon 400 captures at the gun, extraction follows the arc wherever it goes, without requiring the welder to stop and reposition external equipment.
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 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 rubberized 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. 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 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 400 Kit Right for Your Application?
The Falcon 400 Kit is built for MIG welding operations that require source capture at higher amperage. It is the appropriate choice when a lower-rated extraction gun can no longer match the demands of the process. The Falcon 400 Kit is the right choice when:
- 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
Unlike general welding equipment suppliers, every product we design, stock, and support is built around a single problem: removing welding fumes safely and efficiently at the source. When you invest in a Falcon 400 Kit, that focus works in your favour. Our team knows this equipment in detail, from selecting the right wire feeder adapter for your machine to setting the correct airflow balance on the FF100 and identifying the right replacement consumables when your production schedule can’t wait.
Pair It with the Falcon 400 Kit ADVANCED
To realize the performance benefits of the Falcon 400 Kit, we recommend pairing it with our Falcon 400 Kit ADVANCED fume extraction vacuum systems.
The Falcon 400 slots into your existing welding setup without requiring changes to your wire feeder or power source. Connector kits and adapters are available for any machine on the market, so your current investment in equipment stays intact. The complete Falcon 400 product line is designed to grow with your operation whether you are equipping a single station today or scaling to a full production floor down the line, the system integrates without disruption.
| 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
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.