Sounds to me like you are running the KAT500 in AUTO all the time. The same 
happens to my KAT500 when I use it in AUTO on my ZS6BKW that I use on 40m and 
80m.

Could be you are asking the tuner to think too much.
I have found that I can solve this behavior by running it in MANUAL after I 
"teach" the tuner the antenna on both of those bands. If something goes awry 
with the antenna and it deviates from the memorized parameters, the tuner kicks 
off into BYPASS, opens the key line so the amp wont engage, and lets ME make 
the decision as to what to do to fix the problem.
When things are normal, which is about 90% of the time, once I teach it the 
antenna, it remembers the settings and recalls them whenever I QSY and feed it 
a dit from my Flex or knows beforehand where I will be transmitting when I use 
it with my K3. Since my tribander is resonant, it simply bypasses when I QSY 
there. And its convenient to have an antenna switch that knows what antenna to 
use on what band automagically.
Lots of things can affect my very compromise low band antenna to spoil the 
KAT500'ds knowledge of what caps and inductors to use for any particular 
frequency. Running it in MANUAL gets rid of uncertainty for the tuner: If it 
doesnt find the antenna in the condition it expects, it surrenders and lets the 
human in the loop make the decision as to what to do.
Luis Romero - W4LT

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