From 298a9af59e664dc10409b7465e791d8bcb919f12 Mon Sep 17 00:00:00 2001
From: Joseph Doherty <dohejw01@gmail.com>
Date: Fri, 26 Jun 2026 13:15:19 -0400
Subject: [PATCH] fix(deploy): classify AskTimeoutException as a deploy timeout

Akka.Actor.AskTimeoutException does not derive from System.TimeoutException,
so the isTimeout check in DeployInstanceAsync's catch block missed it and
routed it to the generic "Deployment error:" branch. This broke the
DeploymentManager-006 reconciliation query (query-before-redeploy), which
keys off the "Communication failure:" prefix to detect a prior timeout-induced
failure. Add AskTimeoutException to the pattern; add a covering regression test.
---
 .../DeploymentService.cs                      |  2 +-
 .../DeploymentServiceTests.cs                 | 66 +++++++++++++++++++
 2 files changed, 67 insertions(+), 1 deletion(-)

diff --git a/src/ZB.MOM.WW.ScadaBridge.DeploymentManager/DeploymentService.cs b/src/ZB.MOM.WW.ScadaBridge.DeploymentManager/DeploymentService.cs
index 585f42e0..4f410ea9 100644
--- a/src/ZB.MOM.WW.ScadaBridge.DeploymentManager/DeploymentService.cs
+++ b/src/ZB.MOM.WW.ScadaBridge.DeploymentManager/DeploymentService.cs
@@ -353,7 +353,7 @@ public class DeploymentService
             // timed out, that token is already cancelled and the cleanup writes
             // would themselves throw before the Failed status is persisted.
             // Use CancellationToken.None so the failure is durably recorded.
-            var isTimeout = ex is TimeoutException or OperationCanceledException;
+            var isTimeout = ex is TimeoutException or OperationCanceledException or Akka.Actor.AskTimeoutException;
 
             record.Status = DeploymentStatus.Failed;
             record.ErrorMessage = isTimeout
diff --git a/tests/ZB.MOM.WW.ScadaBridge.DeploymentManager.Tests/DeploymentServiceTests.cs b/tests/ZB.MOM.WW.ScadaBridge.DeploymentManager.Tests/DeploymentServiceTests.cs
index 00a3e22e..b79cc6c9 100644
--- a/tests/ZB.MOM.WW.ScadaBridge.DeploymentManager.Tests/DeploymentServiceTests.cs
+++ b/tests/ZB.MOM.WW.ScadaBridge.DeploymentManager.Tests/DeploymentServiceTests.cs
@@ -349,6 +349,63 @@ public class DeploymentServiceTests : TestKit
             Arg.Is<CancellationToken>(ct => !ct.IsCancellationRequested));
     }
 
+    // ── AskTimeoutException: Akka's AskTimeoutException must be classified as a deploy timeout ──
+
+    [Fact]
+    public async Task DeployInstanceAsync_AskTimeoutException_ClassifiedAsTimeout()
+    {
+        // Arrange: first-time deploy with an actor that drops every message, so
+        // the RefreshDeploymentAsync Ask never receives a reply and throws
+        // AskTimeoutException (which does NOT derive from System.TimeoutException).
+        // Prior to the fix this fell through to the generic "Deployment error:"
+        // branch instead of the timeout "Communication failure:" branch, which
+        // broke the DeploymentManager-006 reconciliation that keys off that prefix.
+        var instance = new Instance("AskTimeoutInst") { Id = 99, SiteId = 1, State = InstanceState.NotDeployed };
+        _repo.GetInstanceByIdAsync(99, Arg.Any<CancellationToken>()).Returns(instance);
+        SetupValidPipeline(99, "AskTimeoutInst", "sha256:target");
+        _repo.GetCurrentDeploymentStatusAsync(99, Arg.Any<CancellationToken>())
+            .Returns((DeploymentRecord?)null);
+
+        DeploymentRecord? captured = null;
+        await _repo.AddDeploymentRecordAsync(
+            Arg.Do<DeploymentRecord>(r => captured = r), Arg.Any<CancellationToken>());
+
+        // A 50 ms DeploymentTimeout forces AskTimeoutException immediately
+        // when the actor silently drops every message (never replies).
+        var droppingActor = Sys.ActorOf(Props.Create<DroppingActor>());
+        var comms = new CommunicationService(
+            Options.Create(new CommunicationOptions { DeploymentTimeout = TimeSpan.FromMilliseconds(50) }),
+            NullLogger<CommunicationService>.Instance);
+        comms.SetCommunicationActor(droppingActor);
+
+        var siteRepo = CreateSiteRepoStub();
+        var service = new DeploymentService(
+            _repo, siteRepo, _pipeline, comms, _lockManager, _audit,
+            new DiffService(),
+            new RevisionHashService(),
+            new DeploymentStatusNotifier(NullLogger<DeploymentStatusNotifier>.Instance),
+            Options.Create(new DeploymentManagerOptions { OperationLockTimeout = TimeSpan.FromSeconds(5) }),
+            DeployCommOptions(),
+            NullLogger<DeploymentService>.Instance);
+
+        // Act
+        var result = await service.DeployInstanceAsync(99, "admin");
+
+        // Assert: AskTimeoutException must route through the isTimeout branch.
+        Assert.True(result.IsFailure);
+        // Result error must reflect a timeout, not a generic deploy failure.
+        Assert.StartsWith("Deployment timed out:", result.Error);
+        Assert.DoesNotContain("Deployment failed:", result.Error);
+
+        // The deployment record must be Failed with the timeout-failure prefix
+        // (which the DeploymentManager-006 reconciliation check keys off).
+        Assert.NotNull(captured);
+        Assert.Equal(DeploymentStatus.Failed, captured!.Status);
+        Assert.NotNull(captured.ErrorMessage);
+        Assert.StartsWith("Communication failure:", captured.ErrorMessage);
+        Assert.DoesNotContain("Deployment error:", captured.ErrorMessage);
+    }
+
     // ── WP-6: Lifecycle commands ──
 
     [Fact]
@@ -1900,4 +1957,13 @@ public class DeploymentServiceTests : TestKit
             });
         }
     }
+
+    /// <summary>
+    /// Akka actor that silently discards every message, causing any Ask call
+    /// directed at it to time out with <see cref="Akka.Actor.AskTimeoutException"/>.
+    /// Used by <c>DeployInstanceAsync_AskTimeoutException_ClassifiedAsTimeout</c>
+    /// to verify that the deploy catch block treats
+    /// <see cref="Akka.Actor.AskTimeoutException"/> as a timeout.
+    /// </summary>
+    private class DroppingActor : ReceiveActor { }
 }