25.2V 10.4Ah Li-ion Battery Pack for Battery Powered Backpack Sprayer

25.2V 10.4Ah Li-ion Battery Pack for Battery Powered Sprayer

In April 2025, a battery powered backpack sprayer manufacturer approached CM Batteries with a recurring field problem. Their new higher-flow pump sometimes caused power cuts during spraying. End customers also reported connector corrosion after one full growing season. They needed a redesigned battery pack. It had to handle the new pump’s surge current. It also had to last through a full season of chemical exposure. It had to stay within the original pack’s weight limit. They also could not redesign the sprayer housing.

Within 30 days, CM Batteries diagnosed the root cause, re-engineered the BMS and enclosure design, and delivered a validated 25.2V 10.4Ah 18650 7S4P battery backpack sprayer battery pack that met all performance, sealing, and drop-in compatibility requirements.

Battery Sprayer Customer Overview

The customer is a mid-sized farm equipment maker.It supplies battery-powered backpack and cart sprayers to domestic distributors.It also supplies export partners across Europe. Their product line includes standard backpack sprayers for small growers and higher-flow trolley units for greenhouses and orchards.
As spraying equipment shifts from combustion and manual pumps toward battery power across their target markets, battery reliability has become a direct driver of the customer’s warranty costs and distributor relationships — a single field failure pattern, if left unresolved, affects an entire product line’s reputation across multiple export markets at once.

Power Cuts Mid-Spray

The higher-flow pump’s start-up inrush current exceeded the original BMS’s over-current protection threshold, cutting power every time the pump engaged — even with a fully charged battery.

CMB Solution:
Re-sized the BMS discharge threshold to the pump’s actual measured inrush current, with surge headroom built in to eliminate nuisance shutdowns.

Connector Corrosion After a Season

The original enclosure passed a one-time splash test but wasn’t rated for cumulative pesticide and fertilizer exposure across a full growing season, leading to connector degradation in the field.

CMB Solution:
Redesigned the enclosure with gasket-sealed seams and potted connectors, validated against cumulative chemical and moisture exposure rather than a single splash event.

Backpack Felt Too Heavy for a Full Shift

Hitting the higher-flow pump’s target runtime with the original cell selection pushed pack weight above what operators could comfortably carry for a full working shift.

CMB Solution:
Selected higher energy-density Li-ion cells to deliver 10.4Ah within the original backpack weight envelope — no redesign of the harness required.

25.2V 10.4Ah Li ion Battery Pack

7S4P 25.2V 10.4Ah 18650 Battery Pack Design for Backpack Sprayer Battery Powered

Product Highlights

  • Nominal voltage: 25.2V
  • Capacity: 10.4Ah
  • Discharge capability: High-rate, sized to pump surge current profile (custom per pump spec)
  • Surge/stall response: BMS threshold matched to measured pump inrush current — no nuisance trip under normal start-up load
  • Enclosure protection: IP68 Sealed housing, gasket-sealed seams, potted connectors
  • Certification: UN38.3, CE, IEC 62133-2 Support
  • Weight optimization: High energy-density cells to stay within backpack-appropriate weight envelope
  • Custom options: Voltage platform, capacity, connector type, enclosure material
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25.2V 10.4Ah 7S4P Lithium Battery Operated Sprayer Battery Pack Parameter

No. Item Specification Note
1 Nominal Voltage 25.2V 3.6V/Cell
2 Nominal Capacity 10.4Ah @0.2C
3 Minimum Capacity ≥10.1Ah /
4 Initial Internal Impedance ≤65mΩ AC 1KHZ
5 Standard Charge Voltage 29.4V 4.2V/Cell
6 Standard Charge Current 2A @0.2C
7 Max Charge Current 10.4A BMS Limit
8 Standard Discharge Current 20A @0.2C
9 Max. Discharge Current 40A /
10 Discharge Cut-off Voltage 19.6V 2.8V/Cell
11 Cycle Life ≥800 cycles Retention: ≥80%
12 Charge Temperature 0°C~45°C Standard Charge
13 Discharge Temperature -20°C~60°C Standard Discharge
14 Storage Temperature -20°C~ 45°C ≤3 Months
0°C ~ 25°C ≤1 Year
15 Weight About 1.55kg /

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FAQs-25.2V 10.4Ah Li-ion 18650 Backpack Sprayer Battery Pack

Why does a sprayer battery shut down even when it's not fully discharged?

In most cases, this is caused by the pump’s start-up inrush current exceeding the BMS’s over-current protection threshold — the battery isn’t depleted, it’s being protectively disconnected. The fix is sizing the BMS to the pump’s actual inrush profile, not just its average running current.

How is corrosion prevented in agricultural sprayer battery packs?

Through sealed enclosure design with gasket-sealed seams and potted electrical connectors, validated against cumulative chemical residue and moisture exposure across a full season rather than a single splash test.

Can the voltage or capacity be customized for a specific pump?

Yes — voltage platform, capacity, connector type, and enclosure material are adjusted per your pump’s measured current draw and target market certification requirements. Please contact us today.

Tailored Customization

Our design team can create custom battery designs for just about any device or machine.

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