eVGA is conservative in their recommendations:
EVGA | Products 8 Series Family&sw=
and they want a 350W PSU with a minimum of 18A at +12V. It's not aways safe to just add the capacities of a 2 rail PSU, but I think you're OK.
I doubt that an 8400GS idles as high as 60W. The PCI-E version must, by definition, draw less than 75W fully loaded, and I doubt that the PCI version draws more.
I'm not sure what your problem may be. It sounds like you should have set the BIOS graphics priority to the new graphics card, rather than the onboard controller, but it's not 100% clear from your post that you've already tried that.
The message that you're seeing at startup is from the graphics card BIOS,
not the PC. It doesn't mean that the card is working with the system. It is getting power, though.
Many people with onboard graphics seem to have trouble installing an add-on graphics card. That's cold comfort, I suppose.