Overheat is a situation taking time, and usually starts with a good match, then deteriorating.

In this case ; "But when I throw the KAP1500 in line, it gets all pissed off, throws up and faults out.  Says SWR is 99:1 !!!"

indicating an instant issue while the balun is still stone cold...

The 5kw balun is not the best for your situation, but rather the 4116 3KW hybrid

https://www.balundesigns.com/model-4116-4-1-hybrid-balun-1-5-54mhz-3kw/

See ; https://www.balundesigns.com/blog/baluns-for-multiband-antennas-fed-with-open-wire-or-ladder-line/

73


Adrian Fewster





On 2/9/20 10:12 pm, Bill Johnson wrote:
I would agree that the coil could overheat.  The model number is left out.  The 
Balun Design coil chosen may not be satisfactory for your power despite the 5KW 
rating.  Which Balun are you using?

Bill
K9YEQ

-----Original Message-----
From: elecraft-boun...@mailman.qth.net <elecraft-boun...@mailman.qth.net> On 
Behalf Of David Gilbert
Sent: Tuesday, September 1, 2020 12:28 PM
To: elecraft@mailman.qth.net
Subject: Re: [Elecraft] my KPA1500 and 160M


One distinct possibility is that the 4:1 balun is getting hot at 1500 watts.  
Have you tried running the KPA1500 at a lower power?

73,
Dave  AB7E


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