Well, I thought you were an old hand at Openttd, never mind. Me too, I have yet to play a game in OpenTTD.
To that sprite limit. Yes, the player gets an error message, when trying to start a game and having too many .grfs in the list and the game exits to the desktop.
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Error : Tried to load too many sprites (16'383 max)
Now, this error will happen with v0.5.0 and earlier versions. In the nightlies (don't know from which release onwards) this is no longer a problem as the limit has been increased to an astronomical number. Currently if players are very selective about the .grfs they wish to play with, then there is no problem. This, however, will change when we release the Canadian Stations Set (v0.3) and the Canadian Train Set (v0.3); these sets are so large that you would not be able to play them together in v0.5.0. Using them alone, is currently ok, but forget about adding any other ones.
The good news is, that this has been fixed with the nightlies. You could mention, if above error occurs, to either be more selective what grfs are being loaded or using one of the recent nightlies.
What counts towards the sprite limit ? Every single real sprite in a grf is counted once (never mind how often they are being used). On top of that about 4'000+ base sprites are also included in the count. In TTDPatch you can check how many sprites are being used for a particular grf. Open up the 'New graphics status' window and without any grf selected it will show the active sprite count. Dis/enabling a set will change these numbers and the difference will indicate what the sprite count for that set is.
I hope, this helps
EDIT: I have been beaten by mart3p