Stratix 5700 1783-BMS10CGL Replacement Guide

Overview

The Allen-Bradley Stratix 5700 series has been a cornerstone of industrial Ethernet deployments for over a decade. Built on Cisco technology, these managed switches bridge the gap between Operations Technology (OT) and Information Technology (IT) by utilizing Cisco IOS (Internetwork Operating System) while offering native integration into Rockwell Automation’s Logics designer environment via Common Industrial Protocol (CIP) commands.

The 1783-BMS10CGL is a 10-port Layer 2 Lite Managed Switch tailored for mid-sized applications requiring local device segmentation, basic network security, and deterministic EtherNet/IP communication. However, as control networks evolve and component lifecycles phase out, industrial operators must plan for the maintenance, replacement, or modernization of these critical switches. This guide provides a detailed technical roadmap to successfully replace the 1783-BMS10CGL with minimal downtime.

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Legacy Product Information

The 1783-BMS10CGL is a ruggedized, DIN-rail mounted Layer 2 Lite switch. It is engineered to withstand harsh industrial environments, with an operational temperature range from -40°C to +60°C and IP30 protection. It features dual power inputs for high-availability systems.

Key Specifications:

• Total Ports: 10
• RJ45 Fast Ethernet Ports: 8 (10/100 Mbps)
• Combo/Dual-Purpose Ports: 2 Gigabit ports (each port can operate as a 10/100/1000 Mbps copper RJ45 or a 100/1000 SFP slot for fiber optic connections)
• Firmware Feature Set: Layer 2 Lite (Supports IGMP Snooping, DHCP persistence, IEEE 1588 CIP Sync, local MAC-based port security, and VLAN segmentation up to 64 IDs)
• Input Voltage Range: 12 to 48V DC redundant terminal block connection (nominal 24V DC)
• Physical Dimensions: 130mm H x 91.4mm W x 109.2mm D (5.1 in x 3.6 in x 4.3 in)
• Weight: ~1.25 kg (2.75 lbs)

Historically, this switch functioned as a workhorse in localized skid integration, conveying systems, and medium-scale PLC-to-HMI applications.

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Recommended Replacements

When upgrading or replacing a 1783-BMS10CGL, several options are available depending on whether you want to perform a drop-in legacy replacement, modern hardware migration, or full feature set upgrade.

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Compatibility Considerations

When migrating from a legacy 1783-BMS10CGL to a newer switch like the Stratix 5200 (1783-SMS10CGL), several key technical aspects must be addressed:

1. Device Profile (AOP) compatibility in Studio 5000 Logix Designer

To access internal diagnostics, alarms, and port status in a ControlLogix or CompactLogix controller, the matching Add-on Profile (AOP) must be installed. The Stratix 5700 relies on older AOP installations. Selecting a Stratix 5200 series switch requires downloading the updated Stratix 5200 AOP files from the Rockwell Automation Product Compatibility and Download Center (PCDC).

2. Configuration Storage (SD Card Migration)

The Stratix 5700 supports configuration saving and disaster recovery via a standard SD card (typically 1783-MCG or 1783-SDHC8G). You cannot plug a Stratix 5700 formatted SD card directly into a Stratix 5200 or 5800 switch and expect it to boot seamlessly. The configuration file structures and operating systems (traditional Cisco IOS versus IOS-XE) differ. For direct 1:1 identical replacements, the SD card remains the easiest disaster recovery route.

3. SFP Module Matching

Ensure that any Small Form-factor Pluggable (SFP) optical transceivers utilized in the combo ports of the 1783-BMS10CGL are fully certified for use with the new replacement switch. Use only industrial-rated, temperature-hardened SFP transceiver modules (e.g., GLC-SX-MM-RGD or GLC-LX-SM-RGD).

4. Dimensional Footprint

The Stratix 5700 has a width of 91.4mm. The newer Stratix 5200 (1783-SMS10CGL) is slightly narrower (74mm). Ensure adequate cooling clearance is maintained around the replacement unit: 50.8mm (2 inches) of space on the top and bottom, and 25.4mm (1 inch) on the sides.

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Upgrade Benefits

Upgrading from the legacy 1783-BMS10CGL to the Stratix 5200 series (1783-SMS10CGL) delivers several industrial-grade advantages:

• Enhanced Cybersecurity: Newer platforms offer advanced security mitigation tools, including trust anchors, secure boot, and up-to-date cryptographic validation libraries to defend against operational system intrusion.
• Modernized Management Interface: The web interface (Device Manager) in the Stratix 5200 utilizes a modernized, HTML5 responsive GUI. This entirely eliminates issues related to legacy Java dependencies common on older Stratix 5700 firmware.
• Superior Processing Throughput: Modern ASICs yield improved backplane switching capacity, enabling faster network convergence when operating Resilient Ethernet Protocol (REP) loops or Spanning Tree transitions.

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Common Migration Challenges

• Command Line Differences: For OT engineers using CLI scripting, some configurations syntax changed slightly between the older Cisco material on the 5700 and the IOS-XE framework on the Stratix 5200.
• DIP Switch Positions: Unlike older managed networking devices, Stratix configurations default to console-driven or Express Setup. Ensure the hardware resetting or recovery procedures are reviewed prior to field assembly.
• IP Address Conflicts: When utilizing DHCP persistence based on port positions, the newly installed switch must have its DHCP pool allocations, lease states, and MAC association profiles meticulously reassessed.

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Step-by-Step Replacement Procedure

Follow these detailed steps to perform a safe and efficient replacement of a Stratix 5700 1783-BMS10CGL.

Phase 1: Pre-Migration Backup (On-line Switch)

1. Log into the existing 1783-BMS10CGL switch using its Web Device Manager interface or via secure command shell (SSH).
2. Execute the CLI command: copy running-config startup-config followed by: show running-config
3. Copy the running configuration text format and save it on a secure server as a fallback.
4. If a configuration SD card (1783-MCG) is installed, log into the Web Device Manager and verify that the sync status to the SD card displays "Synchronized".

Phase 2: Hardware Demobilization (Lockout/Tagout)

1. Isolate and physically lock out the 12/24/48V DC power source feeding the switch's terminal block.
2. Label each connected Ethernet cable with its corresponding port number (Ports 1 to 8 Fast Ethernet, Ports 9 and 10 SFP Combo).
3. Unplug all RJ45 cables. Retract any dual-purpose SFP optical fibers with care to prevent clean-face contamination.
4. Use a flathead screwdriver to unlock the wire retention terminals on the redundant DC power plug. Pull the block out of the socket.
5. Release the DIN-rail locking tab behind the chassis and unmount the legacy switch from the DIN rail.

Phase 3: Mounting and Cabling the Replacement Switch

1. Snap the replacement switch (e.g., 1783-SMS10CGL or a new 1783-BMS10CGL) onto the 35mm DIN rail. Ensure correct vertical alignment and standard ventilation space.
2. Insert the SFP modules (if fiber linkages are utilized) into the SFP transceiver cages on ports 9 and 10.
3. Plug in all pre-labeled RJ45 connections to their respective ports.
4. Re-terminate the DC supply lines to the removable terminal block plug. Secure the plug back into the switch power headers.
5. Restore control circuit power. Verify the PWR A (and/or PWR B) LED lights continuously green.

Phase 4: Initial Commissioning and Configuration Restore

• If doing a 1:1 replacement with an identical 1783-BMS10CGL via SD Card:
  1. Turn off switch power. Insert the original formatted setup SD card into the new switch’s slot.
  2. Power up the switch. The bootloader parses the configuration files on the SD card directly.
  3. Monitor the bootup progress. Once complete, verify the EIP and Setup LEDs light steady green.
• If migrating to Stratix 5200 (1783-SMS10CGL) or clean configuration setup:
  1. Access the Express Setup page by configuring your engineering workstation to a static IP address in the 169.254.0.x subnet.
  2. Plug directly into switch Port 1. Navigate your web browser to 169.254.0.1.
  3. Complete the initialization prompt (admin credential generation, Management IP address assignment, Subnet mask, and Gateway definitions).
  4. Apply custom VLAN distributions, Smartport configurations (set PLC ports to Multi-device or automation device templates), and set IGMP Snooping flags.

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Frequently Asked Questions

Can I run a Stratix 5200 switch in the same industrial loop as a Stratix 5700?

Yes. They both execute standard industrial networking protocols (REP, STP, IGMP, RSTP). Resilient Ethernet loops combining Stratix 5700 and Stratix 5200 elements operate symmetrically without protocol collision.

What is the role of the "L" in 1783-BMS10CGL?

The "L" designates the Layer 2 Lite firmware version. It supports basic managed Layer 2 switching capabilities but lacks advanced security protocols, routing tables, and full network access control (e.g., 802.1x) included in the "N" (Full Layer 2) or "P" (PoE) models.

How do I configure IP routing on my replacement switch?

The 1783-BMS10CGL is a L2 Lite switch, meaning it does not support L3 static or dynamic routing. If you require inter-VLAN routing natively inside your industrial panel switch, you must upgrade your replacement selection to a Full Layer 2/3 unit, such as the Stratix 5800 series (1783-HMS10C4).

Can I hot-swap the SFP modules when replacing the switch?

Yes. SFP transceivers are hot-swappable devices. However, disconnecting fiber optic lines during active data transmsission is not advised. Always isolate administrative interfaces before moving physical layer equipment.

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Related Products & Families

• Stratix 5700 Series: 1783-BMS10CGN (Layer 2 Full), 1783-BMS10CGP (Layer 2 with PoE)
• Stratix 5200 Series: 1783-SMS10CGL, 1783-SMS10CGN
• Stratix 5800 High-Performance Series: 1783-HMS10C4
• Accessory Components: SFP Transceiver Modules (GLC-SX-MM-RGD, GLC-LX-SM-RGD), Power Supply units (1606-XLS-series)

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Need Help?

Replacing critical network switches in an industrial manufacturing environment requires precise execution to avoid costly commissioning delays. If you are preparing to migrate your network or need to procure replacement hardware, contact us today.

At Palm Parts Solution, we carry a robust inventory of new, refurbished, and certified surplus Allen-Bradley automation components. All of our units—including obsolete and legacy hard-to-find models—are comprehensively tested by technical specialists and backed by our complete warranty protection. Reach out to our engineering support division to source your next replacement part.