BTW, changing out the thermocouple involves removing the hopper, auger, motor and power supply. We are going to focus on pellets right now.
I replaced the Thermocouple in mine (sent free from Weber) and it really didn't make any difference that I could tell. My point is not so much about the relight feature, if it weren't for Lew discovering it, I wouldn't even bring it up. My point is that there is communication within the operation of the SF, and the Glow Plug and should the Glow Plug provide a faulty response, you could be getting the results you're getting. I'm not suggesting that you replace the Glow Plug whenever you get this result (I got it often) I'm suggesting you swap out the Glow Plug, use the hose clamp trick for proper grounding. It's fast and easy to swap out the Glow Plug, just remove the four screws from the back (I got to the point where I didn't even leave the back on) two screws hold the Glow Plug assembly in place, unscrew them, pull out the assembly, make sure the wires aren't damaged, they should be wire guide of the assembly, remove the Glow Plug from the assembly, wire brush it, reinstall it to the assembly, put the hose clamp on the assembly over the ground lever, reinstall the assembly and fire up the SF (after making sure the burn pot is clean) When firing up the SF, you can simply fire it up as you would do normally, or if like me, you put some previously lit pellets in the burn chamber, to speed up the starting process. I had to do this process often, but at least I could use my SF. It was my plan to eventually fix my SF, but I moved and the SF didn't make the trip. I gave it to a member here on the forum who has an IT background, hardware & software. I suspect that he may figure out the problem and hopefully he reports what it is and how he fixed it. Until then, just prepare yourself that prior to using your SF, you may have to swap out the Glow Plug. Note: I said Swap Out; I would not replace the Glow Plug with new Glow Plugs, I would simply swap them out, and when doing so, if a Glow Plug failed to heat, I would toss it. I probably only tossed a couple Glow Plugs in all the years I owned my SF