The size of aquarium a given filter can handle depends as much on livestock as it does on water volume, it will also depend on decor. An aquarium with growing plants, algae, rocks, driftwood, and substrate will be more stable than a bare tank since there's plenty of surface area in the tank for beneficial bacteria to grow on (you're not depending solely on the filters) and the plants and/or algae will consume some of the waste.
That said, my FX5 handles my 6x2x2 just fine by itself (though I've got another smaller canister on it at the moment seeding for a friend), but I wouldn't want to go bigger than 180G for a single FX5 unless lightly stocked. And I'll eventually be adding a second filter to my tank permanently just for redundancy.
Do you have the tank already or is it just what you're considering? I'm not clear on whether you're talking about a drilled tank with a
weir or weirs (which 'overflow' and take the water to the sump) or a hang on style
overflow which is generally use on a tank that isn't drilled. If you don't have the tank yet and want to use a sump I'd get a drilled one with weirs installed which should work out a lot simpler and cheaper than using external overflow boxes. Both weirs and overflows generally have bulkheads to which plumbing is attached to take the water to the sump.
An FX5 plus just about any sump should be adequate for a 250G tank as long as the sump is set up right. You'd probably want a 5000-8000 litre per hour return pump in the sump, a filter sock on the line into the sump, and plenty of ceramic or sintered glass media, that's about it.
It's possible to plumb a canister filter like an FX5 into a weir or overflow if you want to keep intakes and returns out of the tank, but I don't think they're that obtrusive. I think JK47 may have dealt with plumbing an FX5 in that way in his enormous thread:
http://www.monsterfishkeepers.com/forums/showthread.php?t=358278
If he did it was probably within the first 15 or so pages because I don't think I've looked further than that yet.