Ok guys, I did a mist test today. Unfortunately I don't quite know what went wrong. My tests seem to reinforce Mike's observations in that the mist was alot more coarse than expected. I can only wonder if they changed their manufacturing specs or have a whole batch of imperfect nozzles. There is a possibility that my testing method was flawed, so I will explain what I did.
Basically I tried to reproduce the method Cavadge used by making a T off the output of the pump- one side going to my mister and the other to an adjustable valve so I could bleed off just enough pressure to keep the pump's pressure switch from cycling it on and off.
The spray came out alot coarser than expected, and when striking the impingment needle basically made a flat line of spray on each side of the nozzle with some finer mist in between. I didn't have to bother with the valve because even with it all the way closed off and only a single misthead, the flowrate was such that the pressure never reached a level that caused the pressure switch to trigger. I don't know if the fact I didn't bother incorporating the accumulator had anything to do with it (I thought perhaps the pump was cycling so fast I couldn't hear the impulses) but opening the valve only made things worse and the mist even coarser. I remembered tree farmer mentioning there were some bad nozzles in every batch, but I tried 3 and got similar results. The dig nozzles in my garden did indeed make a finer mist even off my 90lb main pressure (pump is supposed to achieve 150 psi, which I doubt it ever did because the fact it never pressure cycled).
I am at a loss here. I don't have any other real life experience with 50 micron mistheads, but I am pretty sure something is wrong, especially because the pump could not keep up with the flowrate of a single misthead. I did not teflon tape the threads anywhere, so perhaps some leakage caused the pressure to never get high enough, but I didn't notice a single drop leaking from anywhere- although there was an unexplainable puddle of water on the counter. I will tighten things up a bit just incase, and try every single nozzle I have and see if I can get any better results. I didn't bother taking any video/pics because the results were so poor. If anyone has any other thoughts, please let me know. For now the only idea I have is that there was some leak somewhere inline that I was not aware of.
EDIT: Okay- so I teflon taped up all the threads and I believe that was the bulk of the issue. The pump began cycling due to the pressure switch being triggered. I felt much better about this now. I adjusted the valve just to the point where it was as closed as much as possible, yet the pump remained steadily on. I did not plumb in a pressure gauge yet, and considering the low tech way I was controlling the pressure, it's quite possible I was not operating at an optimum pressure (I was only using a plastic JG ball valve as opposed to the more precisely adjustable threaded brass valve Cav used). Unfortunately- it seems the nozzle was still not performing as good as I would have expected. It could very well be due to not achieving steady optimal pressure, but I also believe it has to do with the impingement pin- it seems like the mist is not deflecting from it equally in all directions and therefore more of a spray rather than fine mist on one side comes off of it. This could be due to a bad nozzle such a tree farmer mentions, but it is 1am and I already made enough noise for this time of night- lol. The pump was not very noisy once I isolated it by picking it up, but as it lay on the counter is sounded more like a small air compressor. Tomorrow I will plumb in a pressure gauge and test another couple misters. I will also take a pic or two, hopefully I can capture a visual of the mist with proper lighting.
As it was on this test, besides the spray part of the mist that was bad, the other portion of the mist was very fine, even finer than the DIG nozzle mist. The dig nozzle mist reminds me of a plasic spray bottle with a hand squeeze lever and it's spray tip screwed to it's tightest setting, the good portion of the mist from my biocontrol nozzle was nearly invisible, yet I could sense the humidity in the air and see where it has flown all about the kitchen and condensed on various surfaces. If I could get this mist to be the only thing coming out of the mist-head, I think it is exactly what I am looking for, and finer than a DIG nozzle on it's finest setting.