With the air wide open, you're flushing cool air into the stove. You're also blowing smoke past the cat so fast that it can't eat the smoke. Once the cat is lit for 10-15 min, you should see nothing coming out the stack except heat waves. Stove top temp sounds good when you close the bypass, but cut the air to 1/2 or less about a minute before you do that. Then look for the cat to glow (can be hard to see, you may have to move your head around and look from different angles.) You could also pull the cat probe out and see the cat glowing through the hole. Once the cat is glowing, I cut the air further, to almost nothing, and the probe and stove top temps will rise pretty quickly and settle in around 600/1400. It's possible you may need a new cat probe as well, pull it out and if it looks ate up, get a new one. I would GENTLY put a small wooden dowel or something down the probe hole until you touch the cat, to see exactly how long a probe you need. You want the probe within 1/2" of the cat face. woodmanspartsplus has a bunch of different Condar cat probes I haven't seen elsewhere.