But at least it is not completely random. It will always substitute one pen # for the same #. As long as you don't edit your pen colors often, which is bad idea anyway. Once you know the pen associations, then you can modify the pens as needed in PM or even in AC in your template so that it is correct from the get go. In our office, we have template PMKs off to one side of our master layouts that contain the correct plotting pen colors and weights. Simply use the eyedropper and syringe to set the correct line weights.
Do you really want to map 255 pens to their distant pen equivalents?