Fix Healthy condition not updating from Ironic health data

Three bugs prevented the Healthy condition from working correctly
on provisioned hosts:

1. computeConditions was only called inside the actResult.Dirty()
   block. For steady-state provisioned hosts where nothing changes
   during reconciliation, conditions were never recomputed. This
   meant the Healthy condition (populated from Ironic's health
   monitoring API) stayed at its initial Unknown value forever,
   since health status changes externally in Ironic and doesn't
   trigger state machine transitions.

2. Empty health from GetHealth (e.g. when the node is not yet
   registered) was treated as "unknown" via the default switch
   case, overwriting a previously valid Healthy=True on every idle
   reconcile. Now empty health means "no data, leave the existing
   condition unchanged" — only non-empty values from Ironic update
   the condition.

3. conditionsBefore used a slice reference sharing the same backing
   array as host.Status.Conditions. In-place modifications by
   conditions.Set were visible through both references, making
   reflect.DeepEqual always return true. Deep copy the slice before
   comparing so condition-only changes trigger a status save.

Also suppress ErrNeedsRegistration log noise in GetHealth, which
fires on every reconcile before the node is registered in Ironic.

Assisted-By: Claude Opus 4.6
Signed-off-by: Jacob Anders <jacob-anders-dev@proton.me>
(cherry picked from commit 0f32c4f)

Author: jacob-anders

internal/controller/metal3.io/baremetalhost_controller.go

@@ -240,16 +240,23 @@ func (r *BareMetalHostReconciler) Reconcile(ctx context.Context, request ctrl.Re
 		return result, err
 	}
 
+	// Always compute conditions since some (e.g. Healthy) can change
+	// based on external state from Ironic regardless of state machine
+	// transitions.
+	existing := host.GetConditions()
+	conditionsBefore := make([]metav1.Condition, len(existing))
+	copy(conditionsBefore, existing)
+	computeConditions(ctx, host, prov)
+	conditionsChanged := !reflect.DeepEqual(conditionsBefore, host.GetConditions())
+
 	// Only save status when we're told to, otherwise we
 	// introduce an infinite loop reconciling the same object over and
 	// over when there is an unrecoverable error (tracked through the
 	// error state of the host).
-	if actResult.Dirty() {
-		// Save Host
+	if actResult.Dirty() || conditionsChanged {
 		info.log.Info("saving host status",
 			"operational status", host.OperationalStatus(),
 			"provisioning state", host.Status.Provisioning.State)
-		computeConditions(ctx, host, prov)
 		err = r.saveHostStatus(ctx, host)
 		if err != nil {
 			return ctrl.Result{}, fmt.Errorf("failed to save host status after %q: %w", initialState, err)
@@ -2304,15 +2311,17 @@ func computeConditions(ctx context.Context, host *metal3api.BareMetalHost, prov
 		setConditionUnknown(host, metal3api.HealthyCondition, metal3api.UnknownHealthReason)
 		return
 	}
-	switch prov.GetHealth(ctx) {
-	case provisioner.HealthOK:
-		setConditionTrue(host, metal3api.HealthyCondition, metal3api.HealthyReason)
-	case provisioner.HealthWarning:
-		setConditionFalse(host, metal3api.HealthyCondition, metal3api.WarningHealthReason)
-	case provisioner.HealthCritical:
-		setConditionFalse(host, metal3api.HealthyCondition, metal3api.CriticalHealthReason)
-	default:
-		setConditionUnknown(host, metal3api.HealthyCondition, metal3api.UnknownHealthReason)
+	if health := prov.GetHealth(ctx); health != "" {
+		switch health {
+		case provisioner.HealthOK:
+			setConditionTrue(host, metal3api.HealthyCondition, metal3api.HealthyReason)
+		case provisioner.HealthWarning:
+			setConditionFalse(host, metal3api.HealthyCondition, metal3api.WarningHealthReason)
+		case provisioner.HealthCritical:
+			setConditionFalse(host, metal3api.HealthyCondition, metal3api.CriticalHealthReason)
+		default:
+			setConditionUnknown(host, metal3api.HealthyCondition, metal3api.UnknownHealthReason)
+		}
 	}
 }
 

internal/controller/metal3.io/baremetalhost_controller_test.go

@@ -3187,12 +3187,6 @@ func TestComputeHealthyCondition(t *testing.T) {
 		ExpectedStatus metav1.ConditionStatus
 		ExpectedReason string
 	}{
-		{
-			Scenario:       "empty health reports unknown",
-			Health:         "",
-			ExpectedStatus: metav1.ConditionUnknown,
-			ExpectedReason: metal3api.UnknownHealthReason,
-		},
 		{
 			Scenario:       "OK health",
 			Health:         provisioner.HealthOK,
@@ -3232,6 +3226,17 @@ func TestComputeHealthyCondition(t *testing.T) {
 			assert.Equal(t, tc.ExpectedReason, cond.Reason)
 		})
 	}
+
+	t.Run("empty health leaves condition unchanged", func(t *testing.T) {
+		host := bmhWithStatus(metal3api.OperationalStatusOK, metal3api.StateAvailable)
+		fix := &fixture.Fixture{Health: ""}
+		prov, err := fix.NewProvisioner(t.Context(), provisioner.BuildHostData(*host, bmc.Credentials{}), nil)
+		require.NoError(t, err)
+		computeConditions(t.Context(), host, prov)
+
+		cond := conditions.Get(host, metal3api.HealthyCondition)
+		assert.Nil(t, cond, "empty health should not set the Healthy condition")
+	})
 }
 
 func TestComputeConditions(t *testing.T) {
@@ -3331,8 +3336,12 @@ func TestComputeConditions(t *testing.T) {
 				assert.True(t, conditions.IsFalse(tc.BareMetalHost, metal3api.ReadyCondition))
 			}
 			cond := conditions.Get(tc.BareMetalHost, metal3api.HealthyCondition)
-			require.NotNil(t, cond, "Healthy condition should always be set")
-			assert.Equal(t, metav1.ConditionUnknown, cond.Status, "Healthy should be Unknown when health is not reported")
+			if tc.provisioner == nil {
+				require.NotNil(t, cond, "Healthy condition should be set when provisioner is nil")
+				assert.Equal(t, metav1.ConditionUnknown, cond.Status, "Healthy should be Unknown when provisioner is nil")
+			} else {
+				assert.Nil(t, cond, "Healthy condition should not be set when provisioner reports no health data")
+			}
 		})
 	}
 }

pkg/provisioner/ironic/ironic.go

@@ -2004,7 +2004,9 @@ func (p *ironicProvisioner) HasPowerFailure(ctx context.Context) bool {
 func (p *ironicProvisioner) GetHealth(ctx context.Context) string {
 	node, err := p.getNode(ctx)
 	if err != nil {
-		p.log.Error(err, "ignored error while checking health status")
+		if !errors.Is(err, provisioner.ErrNeedsRegistration) {
+			p.log.Error(err, "ignored error while checking health status")
+		}
 		return ""
 	}
 	return node.Health