Not sure what you meant by..."DH checked the propane and the tank was still reading green." Was it the switch over valve indicator (at the regulator) that was reading green or some kind of gauge on your propane tank?
If the switch over indicator remained green, it is odd that that the tank went empty without it turning to red. You said the second tank was originally shut off, so the furnace would have quit when the tank ran out but the switch over indicator should have shown that. (red) The switch over valve would have tried to switch over but couldn't because the second tank valve was shut off.
In any case, if the tank did in fact run out, once your husband turned on the second tank, (as mentioned above) it sometimes takes multiple attempts of the furnace relighting to purge the air from the system.
If I run a tank empty, I always light a stove burner before trying to restart another gas appliance. It sometimes take a minute of purging before gas gets to the burner to light. By purging this way, this keeps other appliances from going into 'lockout mode' from failed attempts at trying to light before the lines are fully purged.
Please post back what you find to be the problem.
It helps other who might be in the same situation.
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