Yesterday I switched my powder drop from my old Lee setup to the Hornady powder drop that came with the press. I got the insert so it flares and drops powder at the same time. I got the case flare looking good and dialed the powder drop to 4.7 gr of Titegroup for my .45 ACP rounds. It worked great. Deviation was maybe .05 gr over ten drops. I started loading rounds one at a time, checking the OAL which was 1.26 and very consistant. The last round I loaded I re-sized/deprimed. Next stage inserted primer. Now I don't remember if this felt smooth or was difficult. It may have been a small primer .45 case and I'm using large, or it may not have seated or it may have seated fine. I honestly don't remeber what happened. I indexed to the next stage to drop powder and flare the case when I heard a primer pop and then a loud bang. Then the powder hopper with almost a full pound of powder burst into flames and looked like a rocket engine with two ft of flames coming out the top. I immediately took off to find a fire extinguisher. I tore through all the cabinets and couldn't find it. I filled up a pitcher with water and ran back downstairs. Luckily the powder burned out without catching the ceiling on fire. I dumped water on the powder hopper since it was still on fire. Looking at the carnage I think the primer did not seat into the round and when the slide went back to pick up the next primer it went off blowing the 100 primers stacked on top of it. It blew apart the primer tube and it shot out of the saftey shroud. This was sharp and blowing up, so I guess it punctured the powder hopper and lit all the powder. Loading pistol rounds the hopper is very close to the top of the primer tube.
Lessons learned:
1. Always have a fire extinguisher at your reloading bench.
2. Verify all .45 brass is large primer type. I'm not sure if this was the cause but it could have been. It could have also been a crushed primer. Some brass just sucks and the primers don't seat.
3. Install metal cover around powder hopper on the side closest to the primer tube. This should prevent anything from blowing through the cheesy plastic hopper tube and starting a 2in rocket engine on the top of my reloader.
I sent Hornady an email telling them what happened to see if they replace the parts. If not I will make some calls. All I know is if the primers explode, (which happens) the powder hopper should not be effected. If I was loading rifle cases it would have been up higher and may not have been an issue. I've used this press for two years so I know what I'm doing, I was really shocked that I've never heard of this happening to anyone else. Be careful out there. Here are some pics of the parts and my ceiling.