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Barbell Horn® Replacement Procedure: Description & Video

[fa icon="calendar"] Aug 26, 2022 11:30:31 AM / by ISM Team

Barbell Horns compatible with BSP-1200

The below step-by-step guide and video illustrate the procedure for replacing Barbell Horns®, using an Industrial Sonomechanics (ISM) bench-scale ultrasonic processor, BSP-1200, as an example. This procedure is used when switching to a Barbell Horn® of the same or, as shown in this example, a different type and can be applied with all ISM ultrasonic processors and horn models. 

Barbell Horn® Ultrasonic Technology (BHUT) is ISM's core intellectual property, which allows our customers to scale-up their applications without having to reduce the ultrasonic amplitude and the associated processing intensity, thereby ensuring reproducible high-quality results on any scale, from lab to industrial. To learn more about why high ultrasonic amplitudes are important, please visit this page.  



Barbell Horn® Replacement Procedure


Barbell Horn® Replacement Procedure:

During this procedure, be sure to use the spanner wrenches provided with your ultrasonic processor. These wrenches are also available on our web store. Do not substitute the spanner wrenches with any other tools. 

use only the provided spanner wrenches to replace the barbell horn
Barbell Horns® and other spare parts for all ISM ultrasonic processors are available on our web store as well. 


  • While the ultrasonic stack is positioned on the support stand, remove and collect the thumb screws with split-lock washers located on the top of the reactor chamber lid. 
  • Loosen the bottom clamp holder, lower the reactor chamber, and remove it from the support stand. 
  • Loosen the top clamp holder and remove the transducer/Barbell Horn® assembly from the support stand by pulling it forward. 
  • Before detaching the horn from the transducer, be sure to remove the transducer’s support arm. Never rely on the transducer’s support arm instead of the spanner wrench during this procedure. 
  • To avoid scratches, we recommend placing a small piece of split silicone hose or another soft material in between the spanner wrench and the transducer. 
  • Insert the pin of the first spanner wrench into a hole in the transducer’s front mass. Hold the wrench against a workbench to prevent counterclockwise rotation. 
  • Insert the pin of the second spanner wrench into a hole in the horn’s input end. Set it up to provide counterclockwise torque. 

barbell horn disassembly procedure

  • Tap the handle of the second spanner wrench with a rubber mallet to generate counterclockwise torque. When the horn turns with respect to the transducer, remove the wrenches and continue to unthread the horn by hand. 

Your horn is now disassembled from the transducer. 


  • Before you assemble the horn with the transducer, inspect all surfaces to be joined for scratches. Contact ISM technical support if you notice any significant irregularities as they may affect operation and cause equipment damage. 

trasducer and horn surfaces1

  • Ensure that the mating surfaces of the two components are clean and smooth (they can be cleaned with ethanol or isopropyl alcohol). These surfaces must make intimate contact for mechanical energy to pass from one component to the next. Pitting or a buildup of dirt on a mating surface will interfere with the energy transfer and reduce the delivered power.
  • Remove any foreign matter from the horn’s threaded stud and transducer’s mating hole.
  • For the flow-through mode only: place an O-ring followed by the reactor chamber lid over the top of the HBH or HBHB-type Barbell Horn®.

flow cell horn assembly during horn replacement

  • Place the provided Mylar acoustic washer over the horn’s threaded stud. 
  • Thread the horn into the transducer by hand.

Purchase ISM Ultrasonic System Spare Parts

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Screen Shot 2022-08-17 at 6.52.43 AM

  • Use the same piece of split silicone hose or another soft material in between the spanner wrench and the transducer to avoid scratches. 
  • Insert the pin of the first spanner wrench into a hole in the transducer’s front mass. Set it up to provide counterclockwise torque. 
  • Insert the pin of the second spanner wrench into a hole in the horn’s input end. Set it up to provide clockwise torque. 

barbell horn assembly procedure

  • Firmly press down with your palms on the wrenches, using the weight of your body to generate counterclockwise and clockwise torques on the transducer and the horn, respectively. The horn is now assembled with the transducer.
  • After attaching the horn, perform the Scan Stack Procedure described in the ultrasonic processor User Manual

Congratulations! You have now completed the horn replacement procedure.

Note: any unusually loud screeching noise coming from the transducer/horn junction likely indicates that the parts have been assembled improperly. If this happens, disassemble the horn from the transducer and repeat the assembly procedure following all instructions. 


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About ISM

ISM is a research & development, equipment design, and process consulting firm, specializing in high-intensity ultrasound for the cannabis, pharmaceutical, nutraceutical, and cosmetics industries. Our laboratory, bench, and industrial ultrasonic processors in conjunction with All-In-One NanoStabilizer®-LT and LSO enable our customers to make their own top-quality cannabis liquid and powdered nano-formulations at any scale. 


  • Ultrasonic liquid processors
  • NanoStabilizer® products
  • Guides/SOPs/Customer Support
  • Rapid onset of action
  • Increased bioavailability
  • Solubility in all beverages and other water-based products 
With ISM' Barbell Horn Ultrasonic Technology (BHUT), one can expect reproducible post-scale-up results, where the production rates are increased by orders of magnitude with no loss in the finished product quality. Additional information on BHUT is available in the following short video:

If you have any questions, please leave your comments below or contact us.

Topics: Ultrasonic Processing Systems