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External Flash not flashing sometimes

I'm really not technically savy enough to know exactly what is causing the problem but my 60D will not work with my sunpak unless it set to auto. When I set it for manual the camera starts but doesn't complete the cycle. Then show an err code. When researching the error code I can only find information about not compatible flash. It works fine in auto mode and seems to communicate with the camera fine. I'm not sure if the OP's camera was having compatibility issues also. That's what I was thinking anyway.
 
you might be overheating your flash. Also, are you using a secondary battery pack?
 
with a canon when you look through the view finder there is a litttle flash symbol that tells you your flash is ready to go and recycled im sure nikon has one is that on? if so communication problem if not recycle problem.
 
You can indirectly adjust the re-cycle time. Yes, Nikon has a viewfinder indicator to let the photographer know when a Nikon flash unit is again ready. The Sigma flash unit the OP has may not.

The re-cycle time is longest when the flash unit is used at full power. Re-cycle time gets shorter as the flash power level is lowered.
You can set the flash power level lower by putting the unit in manual mode.

The OP should be able to download the flash unit's user's manual from Sigma's web site.
 
Sync speed shouldn't affect it; the camera will produce trigger voltage each time the shutter trips, ergo, the flash should fire each time. Sync speed will affect whether or not you get the whole scene in the frame however. I think the most likely causes, in order are: Worn batteries causing longer than normal recycling times, flash not properly seated causing intermittent contact with the camera, a defect with the flash.

My flash physically will not fire if I go over my sync speed, even my on camera pop up flash won't fire.
 
I vote re-cycle time. If you are shooting in close quarters, you should be able to get away with turning the flash power way down to speed up the recycle time. Also carry plenty of batteries. Buy some rechargeable ones, since you will probably switch them out before they are completely dead anyway simply to get better recycle times. Either that or get a battery pack if there is one available to use with the flash that you have.
 
If you are using the flash on full power it will take time to charge up, how long are you waiting before your next shot ? the only ways to get a fast recycle is external battery or turn the power of your flash down and iso up on your camera
 
My flash physically will not fire if I go over my sync speed, even my on camera pop up flash won't fire.

If I go over 1/8000, my flash won't fire either. :D
 
If I go over max x-sync speed with a flash attached to the hot-shoe, my camera (1N RS - 35mm) automatically changes the shutter speed to 1/250th (x-sync speed) with a half press of the shutter release.
 

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