SOURCE: sunpack 544 flash
There can be more than one reasons for that.
1. Broken wire at sync terminal.
2. Electronic sync issue:
2.1. Faulty sync thyristor (CR02).
2.2. Faulty trigger transformer
2.3. Any other passive component around the previous two.
3. Broken sync lead to the flash tube.
4. Broken leads to the main terminals of the flash tube.
5. Electronic fault at main thyristor.
5.1.Faulty main thyristor.
6. Faulty flash tube.
7. Other, like crack on the PCB.
Good luck! :)
If you happen to decide to part with your faulty flash, please consider to write me first, I offer it a good home... best regards, Laszlo klaci(at)index(dot)hu
SOURCE: How does the Sunpak Auto
When internal cells are fully charged it do not need external ones
http://www.photographyreview.com/mfr/sunpak/flashes/PRD_84012_3121crx.aspx
SOURCE: Sunpak 522 and 544 always firing full power
Laszlo is likely correct, the turn-off circuit isn't working to cut the flash off. It can be either the capacitor or the SCR (thyristor). Its like micro-surgery to take one of these flashes apart, but it's possible. My Metz 45CT-5 did the same thing, it was a faulty turn-off thyristor.
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