Is there any way to know for sure the catalyst is active if it’s below the glowing level of heat? If the bypass is closed and the cat temp is rising is that proof it’s definitely working? Or is it possible the temps would rise and the fire would appear healthy to the eye even with a non-active cat?
Yes, if the cat gauge on the top of the stove says it's active, then it's active, even if it's not glowing. Active means it's above 500-ish F. And that does not yet emit visible light.
Often I can see the cat gauge rising when I dial down the thermostat (with, of course, the bypass already closed).
I.e. I reload while the cat gauge is still showing active. My wood is 80 F (b/c it's been near the stove for 24 hrs or more).
Once I close the door, I let the flames do their thing for about a minute (i.e. blowing the room temp air from the box). Then I close the bypass. Then I let it run wide open for a bit, depending on how fast all the splits "engage" with the fire. Then I dial down in steps.
If my "wide open" time was short (becuase the wood is really dry and fire spreads fast), the cat gauge is not yet very high, and then dialing down, I can see it go up while going to less flame.
The point is the cat gauge is not an indicator of "healthy fire". In fact, it is often the opposite - but you CAN run with an unhealthy fire (a smoldering mess) *because* the cat cleans up the mess before it gets to your chimney.
Running low, with little or no flame creates a lot of partially combusted gases and particles (smoke) - that is what the cat combusts and what leads to a high temperature of the cat. So dialing down the air (removing primary flame) can lead to a hotter cat.
Don't worry too much. Trust the cat gauge.
And verify occasionally that indeed you're running without smoke when there are no flames in the stove. (A no flame smolder in the first half of the burn will always produce smoke. If you don't see any, you're good.) That is the pudding that contains the proof.
Occasionally you will see some smoke because (I think) the thermostat adjusts the air a bit leading to some equilibration time for the cat during which some smoke makes it through. That's okay. And there'll be a lot of smoke when charring a new load (in my experience). That is what it is. Nothing I can do about that.