I built my machine and been running it for around 6 months. Then I decided to purchase a Promo THC controller and install it, after I installed it I found that my USB controller card did not support THC function. So I purchased a ESS from the people at warp9td and installed it without any issues and now my THC is working. But I've noticed an issue now and I haven't found whats causing it, when my code is running there is a new pause (around 1.5 seconds) at any line where M03 or M05. As I'm sure you know I was using this for my torch on and off control with my old controller and I was going to use it for the same here as well. But, when I it pauses there and then pauses again for the pierce time it's a lot of dwell time. I did notice the dwell light on mach3 is flashing when M03 and M05 is called. I'm sure its a simple setting I just haven't found it yet..

Ports and pins - spindle setup
set all spin up and down delays to zero, also check on "immediate off"

might be that

Thanks that was it. Since you seem to be the man with the answers I have one more question. I started off my cut as normal zeroing out all axis in the bottom left corner of my sheet, as I have been doing since I started. Right now, I'm using a piece of paper to zero Z axis placing it between the sheet and gun until I detect a slight drag and then zero it out ( one day I will add the material detection, baby steps).  I made some cuts with THC off and the machine worked as normal before upgrading to the ESS. I hit the goto zero and all axis went to zero and stopped. But when I turned the THC on it works THC (raising and lowering the gun while cutting). But, when the cut was finished I selected all to zero Z went way past trying to go 0.100 through the sheet. I did this test few times and confirmed it only occurs after I cut something with THC on, it will not do it with THC off. It's like its actually changing the ZERO position when THC is on? I'm sure its a setting, but with a $500 mechanical torch I want to make sure I'm chasing the problem in the right direction.

Thanks in advance.

Glad it worked

I've certainly not got all the answers - still learning and unfortunately have no experience the ESS at all, without knowing exactly how the THC works on the ESS its hard to say but it does seem as it changing the Z zero ref which is very odd.

When you did the go to zero, the torch went 0.1 through the sheet but did the DRO show zero or -0.1 etc???