THE PLC LAWS

Courtesy of the Members of MRPLC.COM

PLC LAW 0.1 - I AM THE LAW
PLC LAW 1 - DON'T OVERCOMPLICATE THE SIMPLE.
PLC LAW 2 - MAKE SURE YOU PLUG THE CABLE IN BEFORE YOU TRY TO
FIGURE OUT WHY YOU CAN'T GO ONLINE.
PLC LAW 2.1 - JUST WHEN YOU HAVE EVERY CABLE, CARD, GADGET
AND GIZMO FOR YOUR PLANT/SITE. SOMEONE WILL CHANGE
{IMPROVE} THE HARDWARE
PLC LAW 3 - DURING STARTUP, ALWAYS VERIFY I/O BEFORE TESTING THE
PROGRAM
PLC LAW 4 - WHEN CONNECTING YOUR LAPTOP TO THE PLC, DON'T TIGHTEN
THE SCREWS ON THE SERIAL CABLE AT THE LAPTOP SIDE.
PLC LAW 5 - READ THE MANUAL BEFORE TRYING TO INSTALL/COMMISSION
AN UNFAMILIAR PIECE OF HARDWARE.
PLC LAW 6 - ALWAYS HAVE ALL POSSIBLE BACKUP FILES (PLUS READ FROM
PLC ETC.) BEFORE STARTING ANY CHANGES...
PLC LAW 6.1 - BACK UP, BACK UP, BACK UP, BACK UP NOT ONLY YOUR
PLC PROGRAMS BUT YOUR PC. I CANNOT EMPHASIZE THIS ENOUGH.
PLC LAW 6.2 THE PROGRAM WILL ALWAYS CRASH AFTER SEVERAL
HOURS WORK WITHOUT A BACKUP.
PLC LAW 7 - ALWAYS DOUBLE CHECK YOU HAVE THE RIGHT CABLES FOR
YOUR CPU TYPE AND BACKUP INSTALL SOFTWARE WITH YOU BEFORE YOU
STEP ON THE PLANE.
PLC LAW 7.1 - WHEN WORKING IN A LAN OR WAN
ENVIRONMENT ALWAYS TRIPLE CHECK PROCESSOR ID'S
BEFORE ERASING AND DOWNLOADING NEW CODE.

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 1

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW 8 - EACH VENDOR HAS THEIR OWN PROGRAMMING SOFTWARE, SO
PLAN ACCORDINGLY.
PLC LAW 8.1 - SOME VENDORS SOFTWARE MAY NOT PLAY
WELL WITH OTHERS... SEE RSLINX...
PLC LAW 8.2 - ORDER THE CORRECT SOFTWARE FROM
YOUR VENDOR INSTEAD OF ASKING FOR IT ON MRPLC
PLC LAW 8.3 - YOU CAN RUN VIRTUAL MACHINES AND INSTALL
DIFFERENT MANUFACTURES PROGRAMMING SOFTWARE ON EACH,
THAT WAY ALL THE LITTLE CHILDREN CAN PLAY TOGETHER.
PLC LAW 9 - WHEN POWERING UP A PLC THE FIRST TIME, MAKE SURE THAT
THE POWER SUPPLY VOLTAGE SWITCH IS SET TO THE RIGHT VOLTAGE.
PLC LAW 10 - TRY TO STAGE AND TEST AS MUCH AS POSSIBLE BEFORE
MAKING BIG CHANGES.
PLC LAW 11 - SPARES SHOULD NOT SIT ON THE SHELF. THEY SHOULD BE
USED FOR TRAINING AND TESTING.
PLC LAW 11.1 - THERE MUST BE SPARES FOR CRITICAL
PARTS!
PLC LAW 11.2 - MAKE SURE YOU LOAD THE CORRECT PROGRAM IN THE
SPARE BEFORE POWERING UP IN A PRODUCTION MACHINE.
PLC LAW 12 - PROGRAMS SHOULD HAVE MANY RUNGS OF DIAGNOSTIC
LADDER THAT CAN BE ENABLED OR DISABLED QUICKLY. THIS INCLUDES
TIMERS FOR TIMEOUTS. THESE DETERMINE WHEN INPUT DEVICES ARE NOT
WORKING PROPERLY. FIFOS ARE GOOD FOR LOGGING REAL TIME EVENTS.
COUNTERS THAT COUNT ERRORS ARE HANDY TOO.
PLC LAW 13 - THE BEST PLC PROGRAMS ARE ABLE TO RECOVER FROM
ERROR CONDITIONS QUICKLY. THIS CAN MAKE A BIG DIFFERENCE TO
OVERALL PRODUCTION.
PLC LAW 14 - ALL PROGRAMS SHOULD BE WELL DOCUMENTED

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 2

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW 15 - MAKE SURE YOU ACTUALLY UNDERSTAND THE QUESTION IN
THE DIALOG BOX BEFORE HITTING "OK"
PLC LAW 16 - REMEMBER TO PUT A PAPER COPY OF THE LATEST PLC
LADDER IN THE ELECTRICAL CABINET.
PLC LAW 17 - WHEN ALL ELSE FAILS, ADD A TIMER, AND A ONESHOT TOO
JUST IN CASE.
PLC LAW 18 - WHEN A NON PLCITE TELLS YOU THAT A MACHINE IS NOT
WORKING BECAUSE OF "PROGRAMMING ERRORS", ASK FOR PROOF BEFORE
CHANGING YOUR MASTERPIECE.
PLC LAW 18.1 - WHEN THE MACHINE IS DOWN, THE BLAME
WILL BE ASSIGNED TO WHICHEVER COMPONENT THE
PERSON ASSIGNING THE BLAME UNDERSTANDS THE
LEAST.
PLC LAW 18.2 - AMERICAN MONEY SAYS "IN GOD WE
TRUST" - WITH PLC'S ALL OTHERS BRING RELEVANT
DATA.
PLC LAW 18.3- IT'S ALWAYS A PROGRAM/ELECTRICAL PROBLEM UNTIL
YOU CAN PROVE IT'S NOT.
PLC LAW 19 - MAKE SURE THAT YOUR PLC AND OR PROCESS WILL RUN
WITHOUT THE HMI (IF USING ONE).
PLC LAW 20 - A GOOD PROGRAMMER WILL NEVER BELIEVE THE GUY WHO
SAYS NOTHING HAS CHANGED SINCE IT LAST WORKED.
PLC LAW 21 - MAKE SURE THAT THE DEFAULT SETTINGS DOESN'T CAUSE
THE PLC TO FAIL FROM STARTING TO OPERATE PROPERLY AFTER A
BLACKOUT.
PLC LAW 22 - PLC LOGIC CAN NOT CHANGE BY ITSELF.

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 3

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW 23 - NEVER UNDER ANY CIRCUMSTANCES LEAVE FORCES IN A
PROCESSOR. THEY SHOULD ONLY BE USED FOR TEMPORARY TESTING
WHICH MEANS REMOVE THEM BEFORE GOING OFFLINE
PLC LAW 23.1 -- NEVER, EVER, PUT A FORCE IN PLACE UNLESS YOU
ARE 100% CERTAIN OF THE REACTION OF THE LOGIC/EQUIPMENT.
PLC LAW 24 - ALWAYS BE SURE THAT THE RUNG / LADDER / BLOCK YOU ARE
TROUBLESHOOTING IS BEING SCANNED BEFORE YOU MAKE MAJOR
CHANGES OR SPEND 6 HOURS TROUBLESHOOTING IT!!!
PLC LAW 25 - WHEN TEACHING POINTS ON A ROBOT, OR PROGRAMMING A
VISION SYSTEM THAT INTERFACES WITH A MACHINE DESIGNED WITH A DIAL
INDEXER, MAKE SURE YOUR INDEX TABLE IS ON STATION...
PLC LAW 26 - THE CONTROLS PEOPLE CAN ALWAYS COUNT ON BEING THE
LAST TO LEAVE AND THE FIRST TO RETURN TO SOLVE PROBLEMS ON ANY
PLC JOB. EVEN WHEN THE PROBLEM IS NOT PLC RELATED.
PLC LAW 27 - SHARE YOUR UPDATED WORK..
PLC LAW 27.1 - AFTER CHANGES, MAKE SURE THEY WORK
PLC LAW 28 - MACHINES WITH INTERMITTENT FAULTS ALWAYS SEEM TO
WORK OKAY FOR HOURS WHEN THE PROGRAMMER IS AT THE LOCATION.
WHEN THE PROGRAMMER LEAVES, THEY MAY START FAILING WITHIN FIVE
MINUTES...
PLC LAW 29 - PROBLEMS WITH CONTROLS AND AUTOMATED SYSTEMS AT
PLANTS HAPPEN EVERY DAY. BUT IT IS ONLY THE DAY AFTER YOU VISITED
ALL PROBLEMS MUST HAVE A CONNECTION WITH YOUR VISIT.
PLC LAW 29.1 - SOME SPECIFIC FAULTS IN CONTROLS AND
AUTOMATED SYSTEMS ARE THERE FOR YEARS ALREADY,
AND THE OPERATORS KNOW EXACTLY HOW TO DEAL
WITH IT. UNTIL THE PLANT SUPERVISOR NOTICES.... THEN
ALL OF A SUDDEN IT IS A MATTER OF LIFE AND DEATH.

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 4

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW #30 - ANY PROBLEM WHICH GOES AWAY BY ITSELF WILL RETURN
BY ITSELF (BUT AT THE LEAST CONVENIENT TIME.)
PLC LAW 31 - CHECK FOR PROPER EQUIPMENT GROUNDING BEFORE POWER
UP.
PLC LAW 32 - DON'T HAVE TO MANY BACKUPS IT WILL LEAD TO CONFUSION,
HAVE YOUR BACKUP IN ORGANIZED WAY IN PROPER PLACE.
PLC LAW 32.1 - WHEN MAKING BACKUPS OR UPGRADING ANY
PROGRAM LOGIC DO NOT UNDER ANY CICUMSTANCES NAME THE
PROGRAM OR BACKUP 'NEW' I.E NEW(MACHINE)PROG.RSS {A/B}
BECAUSE ONCE THIS HAS BEEN DONE A NUMBER OF TIMES, WHO
KNOWS WHICH PROGRAM IS THE NEWEST OR WHEN IT WAS UPDATED
PLC LAW 33 - THE PROGRAM NEVER FAILS.
PLC LAW 33.1 - THE PROGRAM IN THE PLC DOES NOT HAVE A VIRUS.
NO, IT CAN'T GET ONE EITHER.
PLC LAW 33.2 - LOOK, IT REALLY HASN'T GOT A VIRUS, OK? YOU NEED
TO TRUST ME ON THIS.
PLC LAW 34 - THE CHEAPEST PRICE IS NOT ALWAYS THE BEST OPTION. THE
BEST OPTION IS THE LOWEST PRICE FOR QUALITY WORKMANSHIP.
PLC LAW 34.1 - THE LOWEST BID MAY SIMPLY REPRESENT
THE BIGGEST MISTAKE IN ESTIMATING.
PLC LAW 34.2 - THE LOWEST BID MAY SIMPLY REPRESENT
A FEW MORE MISTAKES IN YOUR MACHINE.
PLC LAW 35 - IF THE PROGRAM ALREADY WORKS PROPERLY, DON'T TOUCH
IT
PLC LAW 35.1 - "BROKE " OR "OK" IS IN THE EYE OF THE
BEHOLDER.

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 5

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW 36 - IDIOTS, STUPIDITY AND OTHER PEOPLE PROBLEMS DEFY
COMMON SENSE MOST OF THE TIME.
PLC LAW 36.1 "THERE'S NO SUCH THING AS IDIOT
PROOF, ONLY IDIOT RESISTANT."
PLC LAW 36.2 "ARTIFICIAL INTELLIGENCE NEVER
OVERCOMES NATURAL STUPIDITY"
PLC LAW 36.3 IF YOU WRITE A PROGRAM TO HELP MAKE
A MACHINE "IDIOT PROOF" THE HR DEPARTMENT WILL
JUST HIRE BETTER IDIOTS
PLC LAW 36.4 OZZ VARIANT YOU CAN MAKE THINGS
IDIOT PROOF BUT NOT OPERATOR PROOF.
PLC LAW 36.5- THE PROBLEM IS SOMEWHERE BETWEEN THE FLOOR
AND THE HMI...
PLC LAW 37 - THE MACHINE WILL ALWAYS RUN WHEN YOUR WATCHING,
THEN SUDDENLY STOPS RUNNING OR JAMS UP WHEN THE BOSS WATCHES
OR WHEN YOUR CUSTOMER COMES FOR THE SIGN OFF.
PLC LAW 38 - WHEN ALL ELSE FAILS.....PDPU.....(POWER DOWN POWER UP)
PLC LAW 39 - CREATE A PM FOR REPLACING PLC BATTERYS OR AN ALARM
FOR LOW BATTERY.
PLC LAW 40 - IF YOU CHANGE ADDRESSING, UPDATE THE BACKUP
PROGRAM.
PLC LAW 41 - IN A SYSTEM WHERE A PLC AND A WINDOWS COMPUTER (PC)
EXCHANGE DATA, THE PLC USUALLY ISN'T THE ONE THAT STOPS THE DATA
EXCHANGE.
PLC LAW 42 - SERVICE AGREEMENTS WILL NEVER MEET THE NEEDS OF ALL
PARTIES {ENGINEERS, MAINTENANCE, PRODUCTION AND LEGAL}

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 6

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW 43 - THE PLC CAN ALWAYS BE PROGRAMMED TOOVERCOME ANY
MECHANICAL DESIGN DEFICIENCIES - REGARDLESSOF THE LAWS OF
PHYSICS.
PLC LAW 43.1 THE PLC CAN ALWAYS BE PROGRAMMED TO OVERCOME
ANY AXIS (OR PROCESS) PROBLEMS WHERE NO SENSORS EXIST.
PLC LAW 44 - BEFORE TROUBLESHOOTING ANYTHING MAKE SURE THE
PROGRAM ON YOUR PC IS THE SAME AS THAT IN THE PLC!
PLC LAW 45 - NEVER LEAVE THE RUN/REM/PROG KEY IN A PLC WHERE EVERY
TOM DICK AND HARRIET HAS ACCESS TO THE PLC.
PLC LAW 45.1: NEVER MAKE THE OPERATION OF THE
MACHINE DEPENDENT ON THE POSITION OF THE
RUN/REM/PROG KEYSWITCH.
PLC LAW 46 - IF NO ONE SAW WHAT HAPPENED, THEN THEY PROBABLY HAD
SOMETHING TO DO WITH THE FAILURE.
PLC LAW 46.1 - IF IT HAPPENED ON NIGHT (ANOTHER) SHIFT
THEN THEY PROBABLY DID IT ON PURPOSE SO THAT THEY
COULD SPEND THE REST OF THE NIGHT SLEEPING/DRINKING
TEA/READING/TALKING (PICK ONE!)
PLC LAW 47 - NO MAJOR PROGRAMMING CHANGES AFTER NOON ON
FRIDAYS.
PLC LAW 47.1 - NO MATTER HOW SIMPLE IT SEEMS OR HOW
MUCH THE CUSTOMER BEGS YOU - DON'T MAKE A CHANGE
10MINS BEFORE YOU'RE DUE TO LEAVE SITE FOR THE AIRPORT.
PLC LAW 47.2 TYPE-A PLANE CODE IS THAT CODE YOU WRITE
ON THE PLANE ON THE WAY TO COMMISSION THE MACHINE.
PLC LAW 47.3 - TYPE II PLANE CODE IS THAT CODE YOU WRITE AT THE
PLANT SO YOU CAN CATCH YOUR PLANE HOME.

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 7

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW 48: NEVER EVER EVER EVER SAY "I ONLY NEED TO TAKE THE
MACHINE OFFLINE FOR 10 MINUTES TO FIX THAT..."
PLC LAW 48.1 - NEVER TELL THE CUSTOMER "IT'S JUST A
MINOR PROGRAMMING CHANGE."
PLC LAW 49 - THE ANSWER TO ANY "CAN YOU MAKE IT DO THAT?" QUESTION
IS ALWAYS YES. NO MATTER HOW MUCH YOU WOULD LOVE IT TO BE NO.
PLC LAW 49.1 - LAW 49 REALLY MEANS: "YOU ARE GOING TO
MAKE IT DO THAT. AT NO EXTRA COST AND IN THE NEXT HALF
HOUR RIGHT?."
PLC LAW 49.2- THE TIME ESTIMATE FOR ALL TASK SHOULD BE FOUR
DAYS. EXAMPLE: HOW LONG WILL THIS TAKE TO INSTALL? FOUR DAYS.
HOW LONG WILL IT TAKE TO CHANGE THIS FUSE? FOUR DAYS. FOUR
DAYS COVERS ALMOST ALL THINGS IN LIFE.
PLC LAW 50 - CONSIDER WHAT WILL HAPPEN SEQUENTIALLY WHEN EACH
PART OF THE AUTOMATED SYSTEM FAILS.
PLC LAW 50.1 - THE CODE MUST STOP APPROPRIATELY WHEN
FAILURES OCCUR?
PLC LAW 50.2 - THE CODE MUST BE SAFE WHEN FAILURES
OCCUR.
PLC LAW 50.3 - THE CODE MUST NOT CAUSE NUISANCE
INTERRUPTIONS WHEN A SENSOR STARTS TO FLICKER.
PLC LAW 50.4 - REMEMBER, EVERY PART OF THE CONTROL
SYSTEM IS CONSTANTLY DEGRADING, AND EVENTUALLY,
EVERY PART WILL FAIL.
PLC LAW 50.5 - PRODUCTION FACILITIES AREN'T KNOWN TO
REPLACE PLC PARTS ON A PREDICTIVE, PREVENTATIVE OR
PROACTIVE SCHEDULE.

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 8

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW 51 - ALL CODE THAT CAUSES MACHINERY, HAZMAT, OR HEAVY
PRODUCT OF ANY KIND TO INTERACT WITH OPERATORS IN ANY WAY SHOULD
BE WRITTEN TO PROTECT PEOPLE FIRST, ENVIRONMENT SECOND,
EQUIPMENT THIRD, AND PRODUCTION LAST.
PLC LAW 52 - DON'T TRUST ANYONE'S DESCRIPTION OF A PROBLEM. VERIFY
YOURSELF!!!
PLC LAW 53 - BEFORE MAKING ANY REQUESTED CHANGES, MAKE SURE YOU
UNDERSTAND WHAT IS INDEED REQUESTED. IT IS OFTEN PEOPLE SPEAK
DIFFERENT "LANGUAGES"
PLC LAW 54 IF YOU NEED A GOOD MACHINE LABEL OR STICKER USE A
RULE FROM THIS SECTION.
PLC LAW 54.1 - "IF YOU ARE A PLANT ELECTRICIAN READING THIS,
STOP, STAND BACK AND LOOK AT THE PRETTY LIGHTS"
PLC LAW 54.2 - 'THIS MACHINE HAS NO BRAIN. USE YOUR OWN.'
PLC LAW 55- WHEN PUTTING IT INTO MEMORY, REMEMBER WHERE YOU PUT
IT.
PLC LAW 56- RULE 1: PLUG IT IN. RULE 2: TURN IT ON. THIS SOLVES 80% OF
ALL TROUBLESHOOTING.
PLC LAW 57- A POORLY PLANNED PROJECT WILL TAKE THREE TIMES
LONGER TO COMPLETE THAN EXPECTED. A CAREFULLY PLANNED ONE WILL
ONLY TAKE TWICE AS LONG.
PLC LAW 58- ALL GOOD PROJECTS REQUIRE MONEY, TIME, AND RESOURCES.
YOU MAY PICK ANY TWO.
PLC LAW 59- DOES ANYTHING SAY "THANKSGIVING" QUITE LIKE CRANBERRY
SAUCE? EVERYONE NEEDS A GOOD NON-SEQUITER.

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 9

THE PLC LAWS

Courtesy of the Members of MRPLC.COM
PLC LAW 60 - IN THE ABSENCE OF PROPER CONTROLS DUE TO DESIGN
OVERSIGHT, USING A TIMER MIGHT MAKE IT WORK FOR COMMISSIONING, BUT
6 MONTHS DOWN THE ROAD WHEN EVERYTHING HAS SLOWED DOWN YOU'LL
ARRIVE ON SITE TO FIND THE PARTS ALL OVER THE FLOOR.
PLC LAW 60.1 - WHEN A PART IS WORN OUT, REPLACE IT. COATING IT
WITH WD-40 EVERY SHIFT IS NOT AN OPTION
PLC LAW 61 - DON'T BOTHER BUYING A SUPPORT CONTRACT. MORE OFTEN
THAN NOT THEY CAN'T ANSWER YOUR OBSCURE QUESTION ANYWAY. WHY
ELSE WOULD YOU CALL? CLEARLY IT'S NOT DOCUMENTED. YOUR PHONE
SUPPORT TECHNICIAN IS ONLY LOOKING THROUGH THOSE SAME MANUALS
ANYWAY. NOT EXCLUSIVE TO PLCS, BUT ALWAYS A GOOD LAW ANYWAY ;)
PLC LAW 62 - IF YOU INSTALL AN ADJUSTABLE COMPONENT (FOR
ALIGNMENT DURING INSTALL), MAKE SURE IT IS SECURELY FASTENED
DOWN.

FOR MORE ONGOING PLC LAWS SEE THE FOLLOWING LINK:

HTTP://FORUMS.MRPLC.COM/INDEX.PHP?/TOPIC/9522-PLC-LAW/

2016 Edition
Editor Robert C. Lightfoot
Associate Editor Russ Bartels

Page 10