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I think you are right since the cups are rated for up to 5 lbs of pressure so pumping high pressure into them overloads the nozzle and the water will run over. If you hook it up to a bucket, you will not have that problem and if using a pressure regulator, make sure it is as low as it will go.

It sounds like you have had all types of problems. If you ever need some pre-built waterers, just let me know.

I would recommend sealing them with "potable" pvc cement so that they are water safe for the chickens.

You can use brackets to attach them to the pvc. Like these: