Do I need a chiller?

No cover. Fans in the sump I never thought of that. Where you get those?

What kind of lights? I'm guessing you're using a submerged pump.
I have a 220 gal with a 55gal refugium. I actually have to leave my heater on or my system will cool down to room temperature (low 70's). I like my temp around 80f. I have 2x 300w led about 2.5' above the tank, a 2x 4' fluorescent light over the refugium, and my return pump is external.
Something is causing the heat build up. Is your heater on? Sometimes those crap out.
 
Once it starts getting hot here I run my central air and keep it on the whole summer. My tank stays at 78* and I never get a temp swing. So if you have air run it. If not you probably will need to get a chiller.
 
I think the OP was considering a chiller purchase as a back up to prevent an over heating disaster, since his wife has let the temperature rise to 89F a few times by mistake. I have a chiller on line for a similar reason - my AC system has failed in the last and I'm not willing to take a chance of ruining my tank when I can prevent it. It's saved me a few times over the years.

Chillers are not particularly expensive to run. A 1/10 hp unit which can cool 80g of water draws about 2.2 amps. That's going to cost about 2-3 cents per hour to run. A typical 1/4 hp chiller will cool up to 170g of water and draws about 3.0 amps. So now we're talking about 4-5 cents an hour to run. And keep in mind a chiller isn't likely to run all day and night either. (Consumption figures for AquaEuro chillers, electrical costs based on about 10 cents/kilowatt hour. My sympathies to Californians where this figure won't be accurate).

Chillers do produce heat. Every single electrical device ever made produces heat. But a chiller will still remain effective well into the 90Fs. The heat produced by 2-3 Amps of power draw is not significant.

It's true that chillers should not be operated in small, closed, unventilated cabinets. But if you don't want to run one outside of your stand cabinet, an under cabinet ventilation fan is usually easy & cheap to install and can easily keep the chiller compartment at the same level as ambient room temperature.
 
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