This may not apply to the Archon, but I had a Mesa Mark V that popped when switching channels. It didn't bother me much, but I bought a second footswitch for it to have one at the outside studio I was doing a lot of work in to minimize the amount of stuff I needed to move back and forth (had a second pedalboard there).
Oddly enough, the amp didn't pop with the second footswitch.
Doing some experimentation revealed that the initial problem wasn't in the footswitch, it was in the cable that came with it. Yet everything on the footswitch worked perfectly with the amp. There was just the popping. Go figure!
Not saying this is your issue, but I'd check everything.