New Project with Mesa 7I96 and THCAD-05

That is an issue with the "typematic rate" settings in some BIOS's, i did bump into that issue twice and PCW found a workaround for it,
forum.linuxcnc.org/38-general-linuxcnc-q...elocity-fluctuations

Awesome that did the trick there motors run smoothly now.

I am trying to find the steps in adding the thcad-10 and thcad-05 to my Mesa 7i96 card? I went through the Mesa program to add the encoder ports where does the thcad-05 get added on the card?

Not sure, but i think you have to flash the 7i96 with a firmware for plasma (should have pl in the name), to get 3 encoder inputs.
So wiring the first THCAD to the first encoder pin and the second to the second pin should do the trick.

Got it ok I found this schematic on linuxcnc and I see that a option to add a relay in there do I need to add that if not where do I wire the ohmnic output wire from output of Mesa card to the thcad-5?

There is not really any need for the relay and it would be best if it was not fitted but if you have a water table its best to use it so there is no risk of corrosion if water enters the torch tip. Plasmac has a pin to enable the Ohmic sensing circuit. Use that.