The Latest Hot Air Tool Resources

Frequently Asked Questions: Leister Hot Air Heat Guns

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Leister hot air heat guns are portable, ergonomic and built for many applications—including welding, heating, drying, shrinking and more. This post provides answers to some common questions about Leister heat guns and their applications to simplify your heat gun search.

What is the best Leister heat gun for vinyl wrap welding?

The Leister SONORA S1 is ideal for vinyl wrap welding applications (like car wrapping) for the following reasons:

  • Lightweight and compact design — The tool is only 1.32 lbs. and compact, making it ideal for welding at various angles and in tight areas, both of which are needed when vinyl heat wrapping a car.
  • Minimizes vibrations — A heat gun that vibrates a lot forces your arm to work harder to hold it steady. The SONORA S1, however, reduces vibrations, leading to strain-free welding.
  • Digital display — The SONORA S1’s digital display makes it easier to control the tool’s temperature and keep heat consistent, which ensure a smooth, consistent wrap. 

For more on what to look for in a vinyl car wrapping heat gun, see this blog post.

How much does it cost to replace the heating element in a Leister TRIAC S heat gun?

Replacing a Leister TRIAC S heating element is simple and you can do it yourself. All you need is to purchase a replacement element. The price of a Leister TRIAC S heating element depends on the tool’s voltage: find your tool’s voltage and appropriate heating element on this list

To determine how much the heating element costs, contact IHS’ Leister-certified experts at 800-635-0384 or complete our contact form.

Once you have the element, see this blog post and video for a step-by-step guide to heating element replacement. (The whole process only takes about 5 minutes!)

Which is the best Leister hand tool for welding banner seams? 

When seaming banner membrane sheets, hot air welding offers several advantages over glue, stitching or tape. 

Hot air melts the banner membrane to join two sheets into essentially one continuous sheet, while stitching, glue and tape introduce another substance to hold sheets together. Since stitching, glue and tape seaming methods don’t create a permanent bond, any damage to the seam can escalate quickly depending on weather exposure and wind.

When it comes to welding corners and detail work, we'd recommend the TRAIC AT.

Contact IHS For More Information

For more information or to purchase a Leister hot air heat gun, contact IHS’ Leister-certified experts at 800-635-0384.


Referenced Product





How to Use the Leister TRIAC AT for Banner Welding

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As we've detailed in the past, overlap hot-air welding thermoplastic (TPO, PVC, PPE, etc.) signs and banners creates stronger seams than stitching or glue, and is more precise and efficient. So, if you are in the market for a hot-air hand tool banner welder, consider the Leister TRIAC AT.

The Leister TRIAC AT is ideal for welding detailed banner seams or small repair jobs as it offers a digital display for more precise temperature control. In addition, it is ergonomically designed for strain-free usage and lightweight (just 2.2 lbs.). If you're in the market for an automatic banner welder for complete banner construction, check out the VARIANT T1 or UNIPLAN E.

In this post, we’ll walk you through how to set up the Leister TRIAC AT for banner welding, and then how to operate the tool.

How to Set Up and Pre-Heat the Leister TRIAC AT

All of the TRIAC AT’s settings are regulated from the tool’s e-Drive digital display. This display will cycle through its startup screens when the TRIAC AT is plugged in.

When the screen displays a lightning bolt in the upper right corner, take the following steps:

1. Attach your TRIAC AT’s overlap welding nozzle. An overlap nozzle is a flat, but wide, attachment that effectively delivers hot air between overlapping material sheets. Attach the nozzle by simply pushing it onto the end of the TRIAC AT until it can go on no further.

2. Set your preferred temperature. Turn the e-Drive knob (located on the end of the tool) right to increase the temperature or left to decrease it. The temperature on the e-Drive display will blink as you make your adjustments, and continue to blink until the set air temperature is reached.

There are several types of plastic fabric you might use when banner welding. The following table is a general guide to help you determine your fabric type’s melt temperature.

Material PP PPE PVC Hard PVC Soft
Temperature (°F) 572 572 572 662


This is a general guide, so please reference your material packaging for the proper temperature, and perform a test weld to ensure you are using the proper temperature for the material and environment.

3. Tap the e-Drive button once after setting the temperature to configure the air volume. An airflow icon and bar graph will flash indicating that you are in air-volume-setup mode. Turn the e-Drive knob right or left to increase or decrease air volume.

At this point, allow the TRIAC AT can heat up for approximately 5 minutes. The temperature and up arrow should stop flashing when the tool is fully heated.

To avoid accidentally changing the temperature or air volume settings, lock the e-Drive by pushing in the knob and twisting it 90 degrees left or right. A key icon appears when the device is locked.

How to Banner Weld

As mentioned earlier, environmental conditions (i.e. room temperature, sunlight exposure, moisture) can all effect weld performance. For this reason, it is always a good idea to perform a test weld on material. Learn how to perform a test weld here.

Once you’ve confirmed that the TRIAC AT’s settings work for your material, weld your banner sheets together using the following steps:

1. Overlap your two membrane sheets by 2 in. on a flat, hard surface.

2. Insert the TRIAC AT’s overlap nozzle between the membrane sheets.

3. Place a pressure roller on the top membrane near the end of the nozzle. A hand pressure roller is rolled over the heated banner sheets to force the semi-melted seam surfaces together to create a strong bond.

4. Heat the material for several seconds while simultaneously applying pressure with the roller.

5. Weld this way all along the seam, making sure that as you go there are no gaps or voids along the edge.

Cool Down the Leister TRIAC AT

When you’re done, preserve the life of the TRIAC AT’s heating element by cooling the tool down. Push and hold down the e-Drive button for 1 second.

Unlock the e-Drive by pushing the knob in and turning in 90 degrees the opposite direction you used to lock it. Next, press and hold the e-Drive knob for 1 second. The down arrow will flash and a snowflake icon will appear in the upper right corner of the digital display—indicating the tool is cooling down. This process takes about 5 minutes.

For more information or if you would like to purchase a Leister TRIAC AT, contact Hy-Tech’s Leister-certified experts at 800-635-0384 or


Referenced Product



Hot Air Welding Modified Bitumen with the Leister ELECTRON

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There are two types of hot air welders used to seam weld modified bitumen sheets: automatic welders (i.e. BITUMAT B2), which are ideal for long, straight seams, and hand tools for everything else.

The Leister ELECTRON is a hot-air hand tool that is ideally suited for modified bitumen welding because it can reach the air temperature and volume needed to melt and join this roofing membrane.

In this post, we’ll walk you through how to prepare the ELECTRON for welding and how to use it on modified bitumen seams.

Please Note: Contractors should wear protective clothing, goggles and gloves when welding modified bitumen.

Preparing to Weld Modified Bitumen with the Leister ELECTRON 

Before you begin welding, take these steps to prepare the ELECTRON and your modified bitumen membrane:

  1. Clean your bitumen sheets of any moisture, grease and oil. It is important that the modified bitumen’s surfaces are free of any contaminants. It’s likely a gravel top coat will be present on one side of the sheets, but this can be pushed into the material during the seam weld process.
  2. Check the ELECTRON’s cord and power connection for defects or damage. Inconsistent power can disrupt the tool’s operation, which can lead to inconsistent weld quality.
  3. Attach the ELECTRON’s overlap nozzle (see right). Make sure the tool is completely powered down and cool, and then push the nozzle over the tool’s end until it snaps in place.
  4. Plug in, and then turn on the hand tool by pushing the black switch on the back of the tool.
  5. Turn the ELECTRON’s potentiometer (the red dial) to 9 and allow it to heat up for 4-5 minutes.

Adjust the ELECTRON’s Air Temperature for the Material

To adjust the hot air temperature for the modified bitumen you’ll be welding, first reference the material packaging, or contact the manufacturer for the recommended weld temperature. 

Unlike some other Leister hand tools, like the TRIAC AT, there is no digital display to show the exact air temperature output. To set your ELECTRON’s air output temperature for the material, adjust the red potentiometer dial using the following table.

Potentiometer Setting 1 2 3 4 5 6 7 8 9 10
Temperature (°F) 95 167 248 311 383 473 599 707 743 743

Please Note: These temperatures are general estimates and do not account for the effect a nozzle and adjusting the air filter opening will have on raising or lowering the air temperature.

In addition, when setting the ELECTRON’s air temperature, remember that there are a variety of environmental factors that will also impact the air temperature needed to weld the modified bitumen, including:

  • Ambient temperature
  • Sunlight exposure
  • Moisture (i.e. humidity, dampness)
  • Material thickness

For these reasons, it is always recommended to perform a test weld on scrap material before working on the finished product. A test weld will ensure you have the proper hot air output and welding technique to ensure a strong weld. 

Click here for details on what a good modified bitumen weld should look like, and how to perform a test weld.

Proper Welding Position and Process

After a satisfactory test weld, take the following steps to perform your final weld:

  1. Overlap the two sheets of modified bitumen by 4 inches.
  2. Insert the wide end of the overlap nozzle between the bitumen sheets, and place the pressure roller on the top sheet near the nozzle’s end.
  3. Heat the material for 3-5 seconds, and then begin to apply direct pressure with the pressure roller to secure the bond.
  4. Weld all the way to the seam edge, and ensure there are no gaps or voids.

A strong bitumen weld will have a bead of melted material seep out along the weld seam where the sheets were pressed together.

If you have questions about the information here or are interested in purchasing a Leister ELECTRON, please contact IHS’ Leister-certified representatives at 800-635-0384 or 

Referenced Product




Leister Extruder Comparison: Which One is Right for Your Job?

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Leister extruders offer a range of material output and heat capacities, meaning that some extruders are better suited to certain jobs (i.e. container construction, pipeline construction or civil engineering liners) and materials (i.e. PE, PP, PVC, TPO) than others. Picking the right one for your plastic fabrication or civil engineering work isn’t always easy.  

This guide provides an overview of each Leister hand extruder, including intended material use, material output, physical characteristics and continuous operation capabilities. At the end, we provide an easy to scan product comparison table for your reference. 

If you have any questions about Leister extruders contact IHS at 800-635-0384 or

Leister Extruder Overview

FUSION 2: Built for PE and PP materials, the Fusion 2 offers material output between 2.87 and 3.97 lbs./hr. for a 4mm diameter welding rod. It is perfect for fabrication of objects between 0.23 and 0.59 in. thick. Its compact size, lightweight, ergonomic construction, rotating welding shoe and double-sided, twist-free wire intake make it ideal for welding at all angles. It’s brush motor means it should not be used on projects that require hours of continuous operation.

FUSION 3: Built for PE and PP materials, the FUSION 3 offers a material output volume between 3.94 and 7.94 lbs./hr. depending on the plastic type and rod thickness. It is intended for plastic fabrication and civil engineering work on materials between 0.31 and 0.98 in. thick. With a long, lean design, it is ideal for comfortable welding in high, low and hard-to-reach areas. Its brush motor also means you should avoid hours of continuous operation.

FUSION 3C: The FUSION 3C is similar to the FUSION 3 in every way except that it is shorter and lighter, making it better suited for general plastic fabrication and civil engineering welds. 

WELDMAX: Built for welding PE, PP, PVDF and PA, the WELDMAX is Leister’s smallest extruder at just 3.8 lbs. and 17 in. long. It is designed for light plastic fabrication of thin-walled materials (between 0.16 and 0.39 in.). It offers a material output up to 1.76 lbs./hr., and its brush motor makes it better suited for short work periods. 

WELDPLAST S2: Designed to weld PE and PP, the WELDPLAST S2 is a lightweight, compact, ergonomically designed tool ideal for welding in confined areas or at odd angles. This extruder has a material output between 1.1 and 5 lbs./hr. depending on the material type and rod thickness. This makes it ideal for work on civil engineering and plastic fabrication applications where the material thickness ranges between 0.15 and 0.79 in. Its brushless motor allows for worry-free, continuous operation. 

WELDPLAST S2 PVC: Identical to the WELDPLAST S2, the WELDPLAST S2 PVC is optimized for plastic fabrication welds with PVC-U, but can also be used to weld PE and PP. 

WELDPLAST S2 TPO: Again, identical to the WELDPLAST S2, the WELDPLAST S2 TPO is optimized for welding civil engineering membrane seams made of TPO material. 

WELDPLAST S4: Intended for welding PP and PE materials, the WELDPLAST S4 is a powerful hand extruder capable of outputting between 3.3 and 8.8 lbs./hr. depending on material type and welding rod diameter. This extruder is Ideal for plastic fabrication and civil engineering applications where material is between 0.31 and 1.38 in. thick. Its compact housing reduces noise and keeps components cool, and a brushless motor allows for hours of continuous operation.

WELDPLAST S6: The most powerful Leister hand extruder, the WELDPLAST S6 offers a material output of between 8.59 and 13.23 lbs./hr. depending on the material (PE or PP) and welding rod diameter. Even though it is the heaviest (30 lbs.) and longest (32 in.) Leister extruder, its unique, control-wheel grip and ergonomic design allow for comfortable welding. It is ideal for work on materials ranging in thickness from 0.59 to 1.57 in., and its brushless motor allows for hours of continuous operation.

Detailed Extruder Breakdown

Container Construction Yes Yes Yes Yes Yes Yes Yes
Pipeline Construction Yes Yes Yes No Yes Yes Yes
Landfills / Civil Engineering No Yes No No No Yes Yes
Voltage  230  230  230  120/230  230  230  230
Power  2800  3500  2800  1800/2200  3000  2380  4600
Welding Wire (mm) 4  3-5  3-5  4  3, 4  3, 4  4, 5
Output (lbs./hr.) 2.7 - 4  4 - 7.9 4 - 7.9  0.7 - 1.8  1.3 - 5.1  3.3 - 8.8  8.6 - 13.2
Material Thickness (in.) 0.23 - 0.59 0.31 - 0.98 0.31 - 0.98  0.15 - 0.39  0.15 - 0.79 0.31 - 1.38 0.59 - 1.57
Size (LxWxH) (in.) 17.7 x 3.9 x 8.9  26.4 x 3.5 x 7.1  23.1 x 3.9 x 8.9  17.4 x 3.7 x 10  17.7 x 3.9 x 10.2 22.1 x 4.3 x 11.8  32.3 x 4.6 x 9.6
Weight (lbs.)  13  15.87  15.21  8.38  12.79  19.18  30.86
Digital Display No No No Yes  Yes  Yes  Yes
Motor Startup Protection Yes Yes Yes No No No No
Twist-Free Wire Intake Yes Yes Yes No No Yes Yes
360° Rotating Welding Shoe Yes Yes Yes No Yes No No
Steplessly Adjustable Temp. Yes Yes Yes Yes No No No
Brushless Blower Motor No No No No Yes Yes Yes


If shopping for a Leister hand extruder, ask yourself the following 4 questions before making an extruder purchasing decision.

If you have any questions about Leister hand extruders, please contact IHS’ Leister-certified experts at 800-635-0384 or

Comparing Leister’s Roofing Hot-Air Welders

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When shopping for a roofing hot-air welder, it is important to understand the differences between each product option to ensure you get the right tool, or tools, for your needs. Your decision will largely depend on the roofing membrane type, and the characteristics and size of your roofing project.

Leister, a global manufacturing leader, offers four different automatic and semi-automatic roofing hot-air welders, with each designed to satisfy a specific commercial roofing project need.

In this post, we’ll lay out everything you need to know about Leister’s roof welders, and recommend when to choose which.

Leister Roofing Hot-Air Welder Options

Below is a quick overview of the type of work each welder is designed for: 

VARIMAT V2: The fastest single-ply welders available, the VARIMAT V2 is ideal for large, flat roofing projects that require a lot of straight seam welds of PVC, TPO, ECB, EPDM and CSPE membranes. It performs at welding speeds up to 39.2 ft./min., works on slopes up to 30° and requires only one operator.

UNIROOF E: Smaller than the VARIMAT V2, the UNIROOF E is also a single-ply welder, but is designed for smaller projects, inclined roofs up to 30° and repair work. Built for PVC, TPO, ECB, EPDM and CSPE membranes, it requires only one operator and welds up to 16.4 ft./min.

TRIAC Drive:  This lightweight, handheld semi-automatic hot-air welder is perfect for detail work, confined spaces, steep inclines and vertical surfaces (like parapet walls) on PVC, TPO, ECB, EPDM and CSPE membranes.

BITUMAT B2:  The BITUMAT B2 is a flame-free modified bitumen (APP and SBS) welder. It is designed for basic straight seam welding on large bitumen roofs and welds up to 39.4 ft./min.—with only one operator.

Detailed Roof Welder Breakdown

For a further breakdown of the capabilities and features of each Leister roof welder, we’ve included the table below. 

Roofing Material  Plastic Single-Ply
Modified Bitumen
Designed For Large areas Small areas and repair work Detail work, pitched roofs, parapet walls Large areas
Roof Construction Type Rating
Flat Roof  Excellent  Excellent  Excellent  Excellent
Sloping Roof  Up to 30°  Up to 30°  All angles  N/A
Basic Weld Seams  Excellent  Excellent  OK  Excellent
Detail Work  N/A  Excellent  Excellent  N/A
Temperature Range (°F)  68 - 1,148  68 - 1,112  68 - 1,112  68 - 1,202
Speed (ft./min.)  2.3 - 39.4  3.3 - 16.4  0.16 - 9.8  2.62 - 39.4
Size (LxWxH) (in.)  25.2x16.9x13  16.5x10.6x8.2  11.8x9x15  27.2x19.3x13
Weight (lbs.)  77  34  9.2  88.2
Nozzle Widths (in.)  1.25
Guide Bar  Yes  Yes  No  Yes
Brushless Motor  Yes  No  No  No
Digital Display  Yes  Yes  No  No 
Saved Welding Temp.
and Speed Profiles
 Yes  Yes  No  No


While this post focuses on automatic and semi-automatic welders, Leister also offers a variety of other tools and equipment for roof-membrane installation. For a comprehensive list, reference our post on 6 single-ply roofing tools contractors need or visit our Leister roofing tools and equipment page.

If you have any questions, or need clarification on of this information, please contact our certified Leister representatives at 800-635-0384 or


Referenced Product






Leister Welder Portable Generator Considerations

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Power supply plays a huge role in a Leister hot-air welder’s performance and life. Inconsistent power supply from a portable generator will cause the welder’s performance to suffer and can damage internal electrical components, rendering the tool useless.

In this post, we’ll take a look at what inconsistent power looks like, its effects and what to look for in a portable generator.

What Inconsistent Power Looks Like

Alternating Current, or AC, gets its name because the electricity flow alternates back and forth between positive and negative, creating a sine wave (as seen below). In ideal conditions, this sine wave is a smooth line that flows up and then down consistently over a specific time interval.

Source: Associated Power Technologies

However, many factors can cause inconsistencies, which appear as spikes or valleys on the sine curve. These inconsistencies are known as harmonic distortions.

Power supply consistency is measured in total harmonic distortion—the average percentage a portable generator’s AC flow differs from what it would be under ideal conditions.

The larger and more frequent the inconsistencies, the higher the total harmonic distortion percentage.

What Power Inconsistency Means to Leister Hot-Air Welders

These electric current spikes and valleys can negatively impact your Leister welder’s performance, and even damage internal electrical components.

  • Valleys represent a decrease in electricity flow, which limits the amount of electricity entering the welder. While sporadic, small valleys won’t result in any noticeable effects, large, sustained valleys will cause decreased temperature and airflow despite the welder’s setting, which can translate into a weak weld.
  • Spikes represent electrical surges that flow into your welder. Large surges, or small-to-medium surges over an extended period of time, begin to overheat and damage internal components, like a heating element or control panel. This can shorten the component’s life or, if the spikes are big enough, short out and melt these parts immediately.  

Leister welders with digital displays and control interfaces, like the VARIMAT V2, are often more prone to damage as a result of power inconsistencies because their internal electrical components are more advanced. However, other tools, like the BITUMAT B2 or TRIAC S, can also suffer from power inconsistencies.

What to Look For in a Portable Generator

If you use a portable generator and your Leister hot-air welder regularly sustains damage to heating elements or internal electrical components, or you experience inconsistent weld quality, it may be time to consider a new portable generator.

NOTE: Please speak to an IHS Leister-certified technician before purchasing a portable generator, because inconsistent power may not be the actual cause of your welder’s issues.

Most manufacturers will publish their portable generator’s total harmonic distortion on sales collateral and/or its website. When shopping for a new generator, ask for this percentage for both when the generator is running idle and under full load (all power outlets in use).

The IEEE Standard 519 recommends that computer-controlled equipment, and any allied equipment, such as programmable controllers, use an AC power source with no more than 5% harmonic voltage distortion, with no single harmonic being more than 3%.

While portable generators with lower total harmonic distortions may cost more in the short term, replacing damaged welder components or ripping up and repairing poorly welded roofing systems, pond liners, landfill liners or large signage, can end up costing more in the long term.

If you have any questions regarding portable generators, contact IHS’ certified Leister representatives at 800-635-0384 or

If you are in the market for a new portable generator, our sister company—Hy-Tech Products—offers its own line of portable generators. These generators were designed specifically to operate Leister welding equipment and tools. They operate at 5% total harmonic distortion while idling and 3% under a full load.


Referenced Product





How to Repair a Billboard Seam with Leister Hot-Air Tools

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Billboards are commonly made from tough, weather-resistant plastic membranes because they are often outdoors and exposed to environmental conditions, like wind, rain, snow and direct sunlight. 

While there are several ways to seam the billboard’s plastic sheets, many manufacturers choose to hot-air weld because this method creates a permanent bond between the sheets, versus simply holding the sheets together, as is the case with stitching, glue or tape.

However, if not done properly, hot-air welds can weaken and form gaps or voids over time and with heavy weathering. When this happens, you’ll need to repair these gaps to avoid further damage to the billboard.

In this post, we’ll detail what hot-air welding tools you’ll need, and then outline the steps to repair any billboard seam damage.

Plastic Welding Tools You’ll Need

Before you begin, make sure you have the following tools and accessories at the ready.

  • Hot-air hand tool: A hot-air hand tool, like the Leister TRIAC S, is a lightweight, handheld portable heat source that gives you freedom and flexibility when it comes to welding position, angle and height.

  • Pressure roller: A hand pressure roller is rolled over the heated fabric sheets to force the semi-melted seam surfaces together and create a strong bond.

  • Overlap nozzle: An overlap nozzle is a thin but wide attachment for your hot-air hand tool that allows for the effective delivery of hot air between the overlapping sheets of material.

  • Scrap material: Always have a length of scrap material that is identical in terms of plastic type and thickness to the billboard’s material. Environmental conditions will impact how much heat exposure and pressure are required to ensure a strong weld. The scrap material is used to practice your weld before performing it on the actual billboard.

  • Seam probe: A roof seam probe is used to test weld consistency after the repaired seam has had time to cool. Using a seam probe helps you identify any accidental gaps or voids.

How to Repair the Billboard Weld Seam

  1. Make sure the billboard can be pressed against a hard, flat surface. Without this surface, it will be difficult to generate the pressure necessary to create a strong bond. If one is not available, it may be necessary to take down the billboard to repair it.

  2. Clean the seam surface. Make sure to remove any moisture, dust, dirt or other contaminants. These may affect the material’s ability to weld, and potentially compromise the strength of the weld.

  3. Attach the overlap nozzle to your hot-air hand tool by pushing it onto the end, and make sure it is snuggly in position before turning on the tool. With some types of nozzles, you may need to tighten the fastening screw on the nozzle to secure it to the tool.

  4. Turn on your hot-air hand tool. Adjust the temperature setting to what you believe is necessary to properly weld your material. The required temperature will be based on:

    • The ambient temperature of your work area
    • How much sunlight the membrane is exposed to
    • Moisture (i.e. humidity, dampness)
    • The type of material you’re welding
    • The material’s thickness
  5. After your hot-air hand tool has had time to warm up (approx. 5 minutes), perform a test weld on your scrap material to make sure you have the proper temperature setting and welding technique.

    To quality test your test weld, let the seam cool for 10-15 seconds, and then rip the pieces apart. With a good weld, part of the welded material will be stuck to the other piece, and you will see the material's scrim.

  6. Make sure the final billboard material is as taut as possible without stretching. This will ensure the graphics align properly, and help to avoid wrinkles in the weld.

  7. Slip the overlap nozzle between the gap in the two sheets and allow the hot air to heat up the material for several seconds.

  8. Place the pressure roller near the end of the nozzle between the fabric. Press the heated material sheets together against the flat surface. Move the welder nozzle around to all parts of the seam gap, continuing to roll the pressure roller directly on the heated area. 

  9. When complete, give the area 10 to 15 seconds to cool, and then run the seam probe along the welded seam edge to check for any gaps or voids. If any are detected, re-weld that area as needed.

If you have any questions or are interested in learning more about the proper Leister tools for billboard repairs, please contact IHS at 800-635-0384 or


Referenced Product



How to Replace the Carbon Brushes in a Leister ELECTRON

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The ELECTRON is Leister's most powerful hot-air hand tool. It is perfect for welding different types of plastic materials, modified bitumen, drying and removing coatings

The ELECTRON’s motor includes two carbon brushes. These brushes are used to transfer electricity from the outside of the motor to the spinning winding, or commutator. 

Each carbon brush is attached to a spring (see right) to keep it pressed against the commutator; some also have a small carbon disk at the other end of the spring to support conductivity.

Carbon is used because it is soft enough not to wear down the commutator and still offers good conductivity. The tradeoff is that these brushes wear out with regular use, and will need to be replaced. 

When carbon brushes are worn out, your ELECTRON may:

  • Turn off and on while being used.
  • Make a banging sound.
  • Start to smoke or spark. 

If any of these are happening, check that the carbon ends of the brushes aren't worn down. If they are, replacing the brushes should resolve these symptoms.

The following steps explain how to find, remove and replace the brushes in your Leister ELECTRON hand tool. If you need replacement brushes or require support for your tool, please contact IHS at 800-635-0384 or

Find the Leister ELECTRON’s Brushes


Note: Before performing any maintenance on your ELECTRON hot-air hand tool, be sure the tool is completely cool to the touch, the power is turned off and the tool is unplugged.

1. First, peel back the ribbed, black rubber ring that wraps around the tool just above the top of the green handle, and slide it off the tool. 

2. Remove the 2 screws located under the green casing lip using a flathead screwdriver.

3. Slide the green handle casing off the tool and over the power cord. The tool’s motor should now be exposed.

4. Once the motor is exposed, locate the brushes by looking for a brushed copper flap (or door) located around the middle of the motor body. There should be another copper flap on the opposite side. The brushes are located under these flaps.

Remove and Replace the ELECTRON's Brushes

5. Choose a door and carefully pry it open with a flathead screwdriver to reveal a brush. When you pry open the door, the spring will pop out.

6. Grasp the end of the spring and pull out the old carbon brush. Avoid pulling hard because the spring can come loose. If the brush is stuck, pry back the door more to give it additional clearance.

7. Once the worn carbon brush is removed, insert the replacement brush. The brush is rectangular and the thin ends should face both ends of the tool. 

8. Compress the spring on the brush while simultaneously closing the door. Remember: Patience is a virtue.  

9. Repeat these steps on the other side of the hot-air hand tool.

10. Once both brushes are properly replaced, slide the green handle casing back over the tool’s exposed motor, and reattach it by tightening the two screws you removed in Step 2.

11. Finally, slide the rubber ring back over the tool, and align the ring's interior rib with the groove between the black and green parts of the heat gun. 

Please Note: When you turn the hot-air gun on again, you may hear a small clunking sound while the carbon brush conforms to the shape of the commutator. This is normal, and shouldn't last long. 

If you need replacement brushes or support for your Leister ELECTRON hot-air hand tool, contact IHS’ Leister-certified technicians at 800-635-0384 or 


Referenced Product



4 Questions to Ask Before Buying a Hand Extruder

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Used in civil engineering and plastic fabrication projects, hand extruders are highly effective plastic-welding tools designed to create strong, durable seam welds.

As with most other Leister tools, the company’s extruders offer a range of material output and heat capacities, meaning that different extruders will perform better for some projects and plastic materials than others.

In this post, we’ve outlined the questions to expect when you’re looking to purchase a Leister hand extruder, and how your answers may impact tool suggestions.

1. What type of plastic material(s) are you working with?

Different materials and thicknesses require different levels of heat exposure for proper welding results. For example, under ideal conditions PE has a melt temperature of approximately 260°F, while PVC’s is about 320°F.

Each Leister extruder is designed to work with specific material types to ensure fast, effective welds. Working with a certified Leister representative can help you accurately narrow down your product options based on the material(s) you commonly work with.

If you work with multiple plastics, you’ll want an extruder with a programmable interface that enables you to program heat and material output settings based on the material type. In Leister’s line of extruders, several include pre-configured temperature and material settings for specific plastic types.

2. How will you use the extruder?

Different applications demand different capabilities out of an extruder. For example, a thin PVC pond liner seam won’t require as much preheat time before applying the extruded material as would a plastic storage box, which will take longer to preheat because of its thickness.

Some Leister extruders are designed for fast operation on thin materials, while others are designed to heat up and operate more slowly, on thicker plastics. A Leister representative can help you find the right extruder for your common usages, helping you to avoid poor seam welds, and big messes.

3. What size space will you be working in?

Space restriction is also an important factor to consider when purchasing an extruder, as Leister’s tools come in a variety of sizes. For example, if you’re welding in a narrow tunnel, an extruder like the FUSION 2 may be better than the FUSION 3 because of its shorter length.

4. How long do you expect to continuously operate the extruder?

Frequent use—for example, in a factory setting where your team welds storage box seams 24 hours a day—places certain demands on an extruder’s motor. For continuous operation, you’ll need an extruder with a brushless motor because they tend to be more durable with constant operation.

However, if your extruder will be used for repair work, or for short intervals throughout the day, an extruder that has a motor with brushes may be a suitable option. These tend to be less expensive than their brushless counterparts. 

If you have any questions about purchasing an extruder, please share them in the comments below, or contact one of our Leister certified representatives at 800-635-0384 or


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