Many tuners tried to match anything. At the borderline most of the power
stays in toroids and the tuner smokes.  

Perhaps KAT500 like MFJ-998 reduces the matching range at higher power.

You may try 1:1 balun. I use MFJ-998 at KW level with 80m ladderline and 1:1
balun. No problem matching 160-80m. On higher bands almost all bands matched
with homemade 1:1 balun but fewer with heavy-duty 1:1 commercial balun.

Ignacy





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