This is along the same train of thought I was having reading through this. You want the display temp to stay as stable as possible, so placement of the sensor in the overflow or first chamber of the sump is ideal with the heater in a following chamber. That way you are reading the display temp and not the water you are heating in the sump. If the water is heating up that quickly your flow is to slow in the sump and you probably need to crank it up. It could possibly be the reason your remaining 200w Cobalt couldn't keep up when your first one crapped out.I had the same problems when setting up my tank. I have two 100w BRS heaters on about 50 gal of water. The thing that I found worked best is that they need to be in the absolute highest flow possible, for me this was in the very first chamber directly under the overflow pipes, so that the water is moving very quickly around.
Maybe try a higher flow area, and only one of the 200w heaters? Not sure if the ones you had before were glass or titanium, but titanium will conduct heat more efficiently than glass, so in general I’ve seen titanium’s be much more efficient in heating. Don’t touch them when they’ve been on recently though, they get mighty toasty.
Do the BRS heater not have their own dial or setting to control temp? If they do, I would set one a degree or two below you ink birds set temperature. This way you still have a failsafe if one heater fails in off.