I have some issues with this thread.
1) the OP has never said what cartridge was being loaded
2) Taper crimp or roll crimp?
3) Mention of "taper" at station 2, I believe refers to the expander. It is never needed on an LnL AP, since the powder measure can do the expanding. With lead bullets an M-die might demand a station, but that is not a Hornady die.
4)I wondered if the "pop" might actually be coming from the expander releasing a case.
5)I concur with the advice to reset the die following the instructions exactly. Brass particles in the die is a pretty sure sign of severe crimping and/or variable case length.
As general note. I always sort my brass by head stamp in an attempt to get consistent case dimensions and then ammo quality results for a given die adjustment.