Welcome to the club.... I been there, done that. It is really aggravating. Half burnt logs have been tossed out my back door too....
I believe as you said, you can get a piece of wood raging right in front of the secondary smoke inlet and it just channels right up into the refractory / cat. All the heat is going into the refractory and away she goes..... Draft will increase with stack temp so the problem snowballs and you get very high draft (as you measured) and it just keeps sucking more air.....
This is one of the reasons I added my key damper and sealed around the outside edge. In this scenario now I will clamp that damper shut and kill the draft, eventually things will cool back down, but it can take a 30 min to an hour.
Another thing you can do is get a plate and a magnet for the secondary inlet. I made a plate that fits up against the secondary air inlet and I use the magnet to hold it in place. This will kill the secondary burn, and if you shut down the primary air too things will cool back down. it is a smoking mess but it does keep it from melting down.
I assume you heard the whoosh? Mine makes a very distinctive, air flow / combustion noise when this happens.
Couple other thoughts:
- I have noticed usually (not always) 650 flue gas temp correlates close to 450 on the STT on my stove. I typically engage cat at 450 on the STT (which is about 650 flue gas temp)
- I do not think you did anything "wrong", I would guess it was just a combination of wood placement, wood quality and coal bed location. For some combination of reasons: there was "light" wood right in front of the secondary smoke inlet and the coal bed / airflow was promoting combustion right there.
- When I load, I always try to leave a 2-3" gap in front of the refractory at the bottom to promotes mixing of smoke, flame and air before it goes up into the refractory channels.
- Another solution might be to rake coals toward the front, (or at least away from the secondary inlet) but this will slow down the cat light off if you have a colder stove.....