You either need a new COPS rod or a new COPS altogether. One of two things probably happened, either the COPS rod is worn down, or the rod got pushed down into the sensor strip and broke it. If you're using anything less than a HALO B, be it HALO A, Egg2, Revvy, Ricochet, etc., you'd be wise to set COPS up for the speed of your respective loader. The IR3 board is capped at 20 bps, and the HALO B is the only one that feeds faster than that, so it's the only one you should run without COPS.