IvanHunters 0c7b598304 fix(apps/kubernetes): honour nodeGroup minReplicas in MachineDeployment.spec.replicas (#3233)
Refs #3231 (parts 1 + 2 addressed here; part 3 — intra-file
`cozy_wait_linstor_pool_free` gate + orphan
`default-chk-clickhouse-test-keeper-cluster1-0-2-0` PVC cleanup —
deferred to a separate follow-up PR against
`hack/e2e-apps/run-kubernetes.sh`).

**Do not auto-close the issue on merge** — the hardening work is a
distinct concern and belongs on its own tracker entry.

## Root cause chain (recap from the issue)

`packages/apps/kubernetes/templates/cluster.yaml` hardcoded
`MachineDeployment.spec.replicas: 2` regardless of the nodeGroup's
`minReplicas`. The two render-side
`kubernetes-oidc-{system,customconfig}` bats set `minReplicas: 0` and
delete their `Kubernetes` CR without waiting for readiness — but the
chart still spun up 2 × 20 GiB `replicated` (DRBD) worker `DataVolume`s
each. Their create/delete churn overlapped `kubernetes-previous`, which
then saw slow LINSTOR provisioning (my cozyreport from run 28843794670
shows a ~6-minute gap between the `Kubernetes` CR being created and the
CDI `ExternalProvisioning` event actually firing for the worker root
disk); the tenant node registered late; Cilium's CNI init missed the
12-minute node-join deadline; and the test failed with `cni plugin not
initialized`.

## Changes

Two edits, applied together — the chart edit is a no-op without the test
edit, and vice-versa (dropping `nodeGroups` falls back to the chart
helper's default `md0`, which itself has `minReplicas: 0`, so both
pieces are needed for zero workers to actually render).

### 1. `packages/apps/kubernetes/templates/cluster.yaml`

```diff
 spec:
   clusterName: {{ $.Release.Name }}
-  replicas: 2
```

The field is **omitted entirely** so the cluster-autoscaler owns it
alone. CAPI's MachineDeployment defaulting webhook seeds `spec.replicas`
from the `cluster-api-autoscaler-node-group-min-size` annotation on
Create (documented at
https://cluster-api.sigs.k8s.io/tasks/automated-machine-management/autoscaling
— *"if it's a new MachineDeployment or MachineSet, use min size"*), and
Server-Side-Apply field-manager ownership then keeps chart upgrades from
overwriting whatever value the autoscaler patched in the meantime.

Emitting the field from the chart at all — even with the
semantically-correct `{{ $group.minReplicas }}` — would keep the
helm-controller ↔ cluster-autoscaler field-ownership fight alive:
helm-controller applies with SSA + force-conflicts
(https://fluxcd.io/flux/components/helm/helmreleases/), so every routine
`helm upgrade` re-asserts the chart's chosen value and drains whatever
the autoscaler had patched in the meantime.

### 2. `hack/e2e-apps/kubernetes-oidc-{system,customconfig}.bats`

Drop the explicit `nodeGroups:` block and the paired `storageClass:`
from the render-side CR bodies. The tests only assert on the
KamajiControlPlane and the cozy-realm Keycloak objects — worker plumbing
was never part of their coverage.

After the chart fix, the chart helper's default `md0` (with
`minReplicas: 0`) renders a MachineDeployment with `spec.replicas: 0` —
the resource is still emitted for API-surface completeness but never
creates a KubevirtMachine, never provisions a DataVolume, and never
touches DRBD.

## Verification

### helm-unittest

```
Charts:      1 passed, 1 total
Test Suites: 16 passed, 16 total
Tests:       171 passed, 171 total
```

No suite asserted on `MachineDeployment.spec.replicas` directly, so
nothing needed updating.

### helm template — verify the omit

With `tests/values/common.yaml` (which has `minReplicas: 0`), the
rendered MD carries the `cluster-api-autoscaler-node-group-min-size:
"0"` annotation and **no `spec.replicas` field**. CAPI's defaulting
webhook will fill in `spec.replicas: 0` on Create — no worker
DataVolumes provisioned until scale-out.

With a user CR that sets `minReplicas: 2` (the shape the
`kubernetes-latest` / `kubernetes-previous` bats CRs use), the rendered
MD carries the `cluster-api-autoscaler-node-group-min-size: "2"`
annotation and again **no `spec.replicas` field**. CAPI's defaulting
webhook will fill in `spec.replicas: 2` on Create — byte-identical
topology to the pre-PR chart's fresh-install state (2 workers), but
without the recurring drain-on-upgrade cycle.

### Render-side render walk

`helm template` of the OIDC bats CR bodies (after this PR): 1
MachineDeployment with **no chart-managed `spec.replicas`** and
`min-size: "0"` on the autoscaler annotation. CAPI seeds `replicas: 0`
on Create, 0 KubevirtMachines emitted, 0 DataVolume provisioning
triggered. Test assertions on KamajiControlPlane / KeycloakClient /
KeycloakClientScope / AuthenticationConfiguration Secret are unchanged.

## Upgrade impact

Existing customers stop losing workers on `helm upgrade`. Prior to this
PR the chart re-asserted `MachineDeployment.spec.replicas: 2` on every
Helm action, so a customer running with the autoscaler at, say,
`replicas: 8` would see 6 workers drained on every routine Cozystack
platform bump and then wait for the autoscaler to scale back up in
response to unschedulable Pods. With `spec.replicas` no longer emitted
by the chart, SSA field-manager ownership preserves the autoscaler's
value across upgrades unconditionally.

Fresh installs with `nodeGroups: {}` (the schema default) transition
from "2 workers by default" to "0 workers until scale-out". The chart
helper's default md0 carries `minReplicas: 0`, which is what CAPI's
defaulting webhook seeds `spec.replicas` from. The `values.yaml` /
README / helper docstring / regenerated Go type doc + openAPISchema call
this out explicitly; the release-note repeats it below. See finding 5 in
the paired self-review for the specific `addons.ingressNginx.enabled:
true` interaction operators need to be aware of on fresh installs.

## Test plan

- [x] `helm unittest packages/apps/kubernetes/` — 171/171 passing.
- [x] `helm template` with `tests/values/common.yaml` (minReplicas: 0) —
MD.replicas: 0.
- [x] `helm template` with a `minReplicas: 2` override — MD.replicas: 2
(byte-identical to pre-PR).
- [ ] E2E: `kubernetes-latest` unchanged (spawns its two workers as
before), `kubernetes-oidc-{system,customconfig}` render zero workers,
`kubernetes-previous` no longer flakes on LINSTOR pool pressure
originating from the earlier OIDC suite.

## Notes

- Part 3 of #3231 (intra-file `cozy_wait_linstor_pool_free` gate between
kube sub-tests and the orphan clickhouse keeper PVC cleanup) is **not**
in this PR — worth a separate targeted change to
`hack/e2e-apps/run-kubernetes.sh`, and it's a hardening-only improvement
rather than a root-cause fix. Happy to send it as a follow-up if wanted.

## Release note

```release-note
fix(apps/kubernetes): stop the chart from managing `MachineDeployment.spec.replicas`; the cluster-autoscaler owns the field alone. CAPI's defaulting webhook now seeds `spec.replicas` from the `cluster-api-autoscaler-node-group-min-size` annotation on Create, and SSA field-manager ownership keeps subsequent `helm upgrade` actions from overwriting whatever value the autoscaler patched. Two behavioural changes worth calling out:

- Existing customers: `helm upgrade` no longer drains workers on every platform bump — the autoscaler-held `spec.replicas` is preserved unconditionally. Prior to this change the chart hardcoded `replicas: 2`, which drained back to 2 on every reconcile action.
- Fresh installs with `nodeGroups: {}` (the schema default) no longer come up with two workers by default. The chart helper's default md0 carries `minReplicas: 0`, and CAPI's defaulting webhook seeds `spec.replicas` from that. Operators enabling `addons.ingressNginx.enabled: true` on such a CR must either supply an explicit nodeGroup with `roles: [ingress-nginx]` and `minReplicas >= 1`, or accept that the cluster-autoscaler will bring the default md0 up in response to the ingress-nginx controller Pods becoming Pending on install.
```



<!-- This is an auto-generated comment: release notes by coderabbit.ai
-->
## Summary by CodeRabbit

* **Bug Fixes**
* Rendered `MachineDeployment` manifests no longer set `spec.replicas`,
avoiding chart upgrades overwriting autoscaler-managed sizing.
* **Documentation**
* Clarified `nodeGroups: {}` behavior: a default `md0` is emitted with
`minReplicas: 0`/`ingress-nginx` role, and workers are provisioned only
after an autoscaler-triggering unschedulable Pod or manual scaling;
updated related storage and ingress guidance.
* **Tests**
* Strengthened default node group rendering assertions and adjusted OIDC
e2e manifests to reduce CI provisioning churn.
<!-- end of auto-generated comment: release notes by coderabbit.ai -->
2026-07-08 18:58:32 +03:00
2025-10-08 09:43:34 +05:00
2025-04-01 18:48:14 +02:00
2024-02-08 12:04:32 +01:00

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