With many thanks to those who offered suggestions on this topic, I am reporting 
back what I've learned from myriad experiments over the past several days.   I 
apologize for the length of this post.

As I'd commented in a separate post, the arrangement of a Johnson Matchbox in 
front of the KAT3 ATU is not a preferred or permanent configuration for me.  
However, because it was the configuration I used when I first noticed the TX 
power foldback upon the flashing of the 'HI SWR' message on the display, I kept 
it in place for the experiments.  At no point during the ARRL DX contest 
weekends did I observe the 'HI CUR' warning even when operating at 100 watts.

Experiments I performed:

I experimented on several bands (40, 20, 15 and 10 meters), but report only my 
observations on the 20 meter band.   I first adjusted the Matchbox controls for 
minimum SWR at the midpoint of the U.S. phone subband (14.250 MHz).  Although 
unique to my antenna and feedline length, that minimum SWR was 1.95.  The SWR 
increased to about 2.8 at either end of the phone subband (14.150, 14.350), and 
did not exceed 3.0 at any frequency within the subband.  I cleared the KAT3 ATU 
memory, then executed a single tune cycle at 14.250 MHz.  The ATU easily 
attained a 1.0 SWR.

I set the TX Power control to 100 watts, set MIC GAIN for proper ALC 
indication, and transmitted USB voice on 14.250 MHz.  As expected, no 
indication of 'HI SWR' or power foldback.  I then moved in frequency up and 
down the band without an ATU retuning.  At 14.290 MHz the 'HI SWR' message 
flashed and the TX power was automatically reduced by the K3.  The measured SWR 
as reported by the K3 was 2.8 .  I put the KAT3 in 'BYPASS' mode and measured 
SWR directly at the Matchbox output at 14.290 MHz as 2.3   using my AA-55 
impedance analyzer.  I then tested at 14.155 MHz and again the 'HI SWR' message 
was flashed.  The measured SWR via the AA-55 analyzer was 2.4 .

I was curious if the same 'HI SWR' message would be displayed at the lower TX 
power level of 10 watts at the same frequencies where the 'HI SWR' message was 
displayed with high TX power.  At both 14.290 MHz and 14.150 MHz, no 'HI SWR' 
message was displayed using USB voice.  The raw SWR from the Matchbox output 
remained as before and the ATU was not re-tuned.

There are many more experiments I performed on other bands, but the description 
above is typical of my K3 response to frequency change from the ATU tuning 
point.

My inferences:

I don't know the K3 MCU algorithm's threshold for 'HI SWR' to be displayed, but 
it appears to be dependent on the TX Power setting.  I tried only two test 
power levels, but I suppose that TX Power settings between 10 watts and 100 
watts would result in different responses.  It appears that SWR alone, which 
doesn't change at the selected measurement frequencies, is not the sole 
determinant of the 'HI SWR' condition and TX power foldback.  While high SWR is 
subjective, it appears that SWR values greater than 2.3 are sufficient to 
trigger the 'HI SWR' message and TX power foldback, but only if the 100 watt PA 
module is engaged and TX Power set to 100 watts.  The same SWR values presented 
at low TX power do not result in the 'HI SWR' message and TX power remains at 
the original setpoint (10 watts here).

A more curious observation is that switching out the KAT3 (by placing it in 
'BYPASS' mode) enabled transmission at 100 watts without the 'HI SWR' warning 
at the extreme ends of the phone subband.  The KAT3 does not have a true bypass 
relay like the KAT3A ATU, but instead routes the signal around the series 
inductors and leaves the shunt capacitors disconnected except for their stray 
capacitance via the relay contacts.  The inference here is that the combination 
of the impedance presented to the KAT3 ATU by the Matchbox away from the tuning 
setpoint, and the impedance transformation effected by the KAT3 ** without an 
ATU re-tuning **, can present an impedance to the 100 watt PA module that is 
sensed as 'HI SWR.'  This is only mildly surprising because the L-network of 
the ATU remains fixed away from its nominal ATU TUNE frequency, and the 
impedance at the output of the Matchbox varies primarily in its reactive part 
over the phone subband.  The resistive part of that impedance 
 is about 28 ohms and virtually constant across the band, whereas the reactive 
part varies from minus 25.4 ohms at 14.150 MHz to plus 34 ohms at 14.350 MHz.  
These numbers are, of course, unique to my particular antenna and feedline 
length.

Jim, K8MR kindly provided the practical solution to restore full TX power 
output when the 'HI SWR' message is flashed, and I'll remember it for the next 
time it occurs.  My curiosity was how high must SWR be to trigger that warning, 
and does it depend upon whether the 100 watt PA module is engaged or not.

Does the K3 MCU algorithm for protective TX power foldback take account of the 
current demanded by the PA finals as well as the SWR information coming from 
its SWR bridge?  I don't know the answer to this question and I don't have an 
easy way to measure the peak RF current at the PA transistor collectors (or 
drains, for the KPA3A module).

Bottom line: 'high SWR' is a relative condition based on one's experience and 
expectations.  TX power foldback occurs at modest SWR values in the 2.x range, 
at least in my experience, and may occur more frequently if the KAT3 internal 
ATU is trained/tuned only at a single frequency in the phone subband.  If the 
KAT3 is bypassed, the very same raw SWR presented at the shack end of the 
feedline may be tolerated without the TX power foldback occurring.

I'll refrain from any more posts on this topic, and thanks again to all for 
their suggestions and observations.

73,
Mike, K8CN





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