Consul not starting with helm in K8 Client Pods: Reason: BadRequest (400)

Hi all,
I’m trying to deploy consul in the k8 cluster with 17 worker nodes.
Following is my config file:

global:
  name: consul
  datacenter: AcuityDC1
  # kubectl create secret generic consul-gossip-encryption-key --from-literal=key=$(consul keygen)
  # Run above command for gossip key
  gossipEncryption:
    secretName: 'consul-gossip-encryption-key'
    secretKey: 'key'
  tls:
    enabled: true
    # This configuration sets `verify_outgoing`, `verify_server_hostname`,
    # and `verify_incoming` to `false` on servers and clients,
    # which allows TLS-disabled nodes to join the cluster.
    enableAutoEncrypt: true
    verify: true
  acls:
    manageSystemACLs: true
    # createReplicationToken: true
server:
  replicas: 3
  bootstrapExpect: 3
 # disruptionBudget:
 #   enabled: true
 #   maxUnavailable: 0
 # updatePartition:
  securityContext:
    runAsNonRoot: false
    runAsUser: 0
  nodeSelector: |
    consul.client: "true"
client:
  nodeSelector: |
    consul.client: "true"
ui:
# Add service Loadbalancer for consul ui to be on a random port. Check in kubernetes services
  service:
    type: "LoadBalancer"
  enabled: true
connectInject:
  enabled: true
controller:
  enabled: true
prometheus:
  enabled: true
grafana:
  enabled: true

Consul client and Consul-connect-injector-webhook-deployment:

Failed to load logs: container "consul" in pod "consul-l5rlm" is waiting to start: PodInitializing

Reason: BadRequest (400)

consul-server-acl-init

2021-09-12T15:51:01.207Z [INFO]  No bootstrap token from previous installation found, continuing on to bootstrapping
2021-09-12T15:51:31.208Z [ERROR] Failure: bootstrapping ACLs - PUT /v1/acl/bootstrap: err="Put "https://consul-server-0.consul-server.default.svc:8501/v1/acl/bootstrap": dial tcp: i/o timeout"
2021-09-12T15:51:31.208Z [INFO]  Retrying in 1s
2021-09-12T16:01:20.243Z [ERROR] reached command timeout

consul-webhook-cert-manager

2021-09-12T15:50:59.293Z [INFO]  Updated certificate bundle received for consul-controller-mutating-webhook-configuration; Updating webhook certs.
2021-09-12T15:50:59.496Z [INFO]  Creating Kubernetes secret with certificate: mutatingwebhookconfig=consul-controller-mutating-webhook-configuration secret=consul-controller-webhook-cert secretNS=default
2021-09-12T15:50:59.585Z [INFO]  Updating webhook configuration: mutatingwebhookconfig=consul-controller-mutating-webhook-configuration secret=consul-controller-webhook-cert secretNS=default
2021-09-12T15:50:59.605Z [INFO]  Updated certificate bundle received for consul-connect-injector-cfg; Updating webhook certs.
2021-09-12T15:50:59.786Z [INFO]  Creating Kubernetes secret with certificate: mutatingwebhookconfig=consul-connect-injector-cfg secret=consul-connect-inject-webhook-cert secretNS=default
2021-09-12T15:50:59.794Z [INFO]  Updating webhook configuration: mutatingwebhookconfig=consul-connect-injector-cfg secret=consul-connect-inject-webhook-cert secretNS=default

Kubernetes nodes:

NAME              STATUS   ROLES                         AGE   VERSION   INTERNAL-IP     EXTERNAL-IP   OS-IMAGE                KERNEL-VERSION                CONTAINER-RUNTIME
va-k8s-apps-m1    Ready    control-plane,master          57d   v1.21.0   10.64.116.23    <none>        CentOS Linux 7 (Core)   5.4.108-1.el7.elrepo.x86_64   docker://20.10.5
va-k8s-apps-m2    Ready    control-plane,master          57d   v1.21.0   10.64.116.17    <none>        CentOS Linux 7 (Core)   5.4.108-1.el7.elrepo.x86_64   docker://20.10.5
va-k8s-apps-m3    Ready    control-plane,master          57d   v1.21.0   10.64.116.9     <none>        CentOS Linux 7 (Core)   5.4.108-1.el7.elrepo.x86_64   docker://20.10.5
va-k8s-apps-w1    Ready    frontend,worker               57d   v1.21.0   10.64.116.100   <none>        Ubuntu 20.04.3 LTS      5.4.0-81-lowlatency           docker://20.10.8
va-k8s-apps-w10   Ready    backend,worker                45d   v1.21.0   10.64.116.165   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.7
va-k8s-apps-w11   Ready    backend,worker                45d   v1.21.0   10.64.116.183   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.7
va-k8s-apps-w12   Ready    backend,worker                45d   v1.21.0   10.64.116.184   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.7
va-k8s-apps-w13   Ready    backend,worker                45d   v1.21.0   10.64.116.185   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.7
va-k8s-apps-w14   Ready    backend,worker                45d   v1.21.0   10.64.116.176   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.7
va-k8s-apps-w15   Ready    backend,worker                45d   v1.21.0   10.64.116.187   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.7
va-k8s-apps-w16   Ready    <none>                        37d   v1.21.0   10.64.116.160   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.8
va-k8s-apps-w17   Ready    <none>                        37d   v1.21.0   10.64.116.158   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.8
va-k8s-apps-w2    Ready    frontend,worker               57d   v1.21.0   10.64.116.156   <none>        Ubuntu 20.04.3 LTS      5.4.0-81-lowlatency           docker://20.10.8
va-k8s-apps-w3    Ready    frontend,worker               57d   v1.21.0   10.64.116.161   <none>        Ubuntu 20.04.3 LTS      5.4.0-81-lowlatency           docker://20.10.8
va-k8s-apps-w4    Ready    ingress,worker                48d   v1.21.0   10.64.116.159   <none>        Ubuntu 20.04.2 LTS      5.8.0-63-lowlatency           docker://20.10.7
va-k8s-apps-w5    Ready    backend,worker                46d   v1.21.0   10.64.116.175   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-generic              docker://20.10.7
va-k8s-apps-w6    Ready    backend,worker                46d   v1.21.0   10.64.116.172   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-lowlatency           docker://20.10.7
va-k8s-apps-w7    Ready    backend,worker                46d   v1.21.0   10.64.116.168   <none>        Ubuntu 20.04.2 LTS      5.4.0-80-lowlatency           docker://20.10.7
va-k8s-apps-w8    Ready    backend,worker                46d   v1.21.0   10.64.116.162   <none>        Ubuntu 20.04.2 LTS      5.4.0-81-lowlatency           docker://20.10.7
va-k8s-apps-w9    Ready    backend,worker                46d   v1.21.0   10.64.116.174   <none>        Ubuntu 20.04.2 LTS      5.4.0-81-lowlatency           docker://20.10.7

kubectl get pvc

NAME                           STATUS    VOLUME            CAPACITY   ACCESS MODES   STORAGECLASS   AGE
data-default-consul-server-0   Bound     data-consul-pv0   10Gi       RWO                           18m
data-default-consul-server-1   Bound     data-consul-pv1   10Gi       RWO                           18m
data-default-consul-server-2   Bound     data-consul-pv2   10Gi       RWO                           18m

Consul-server

2021-09-12T15:51:49.303Z [INFO]  agent.server.serf.lan: serf: EventMemberUpdate: consul-server-1
2021-09-12T15:51:49.303Z [INFO]  agent.server: Updating LAN server: server="consul-server-1 (Addr: tcp/172.29.153.17:8300) (DC: acuitydc1)"
2021-09-12T15:51:49.702Z [INFO]  agent.server.serf.wan: serf: EventMemberUpdate: consul-server-1.acuitydc1
2021-09-12T15:51:49.702Z [INFO]  agent.server: Handled event for server in area: event=member-update server=consul-server-1.acuitydc1 area=wan
2021-09-12T15:51:50.583Z [INFO]  agent.server.serf.lan: serf: EventMemberUpdate: consul-server-0
2021-09-12T15:51:50.583Z [INFO]  agent.server: Updating LAN server: server="consul-server-0 (Addr: tcp/172.29.2.207:8300) (DC: acuitydc1)"
2021-09-12T15:51:50.888Z [WARN]  agent: Node info update blocked by ACLs: node=11cc3111-73ed-79d4-6d4c-459b84939c5f accessorID=00000000-0000-0000-0000-000000000002
2021-09-12T15:51:51.182Z [INFO]  agent.server.serf.wan: serf: EventMemberUpdate: consul-server-0.acuitydc1
2021-09-12T15:51:51.182Z [INFO]  agent.server: Handled event for server in area: event=member-update server=consul-server-0.acuitydc1 area=wan
2021-09-12T15:51:56.247Z [INFO]  agent.server.serf.lan: serf: EventMemberUpdate: consul-server-2
2021-09-12T15:51:56.247Z [INFO]  agent.server: Updating LAN server: server="consul-server-2 (Addr: tcp/172.29.192.39:8300) (DC: acuitydc1)"
2021-09-12T15:51:56.643Z [INFO]  agent.server.serf.wan: serf: EventMemberUpdate: consul-server-2.acuitydc1
2021-09-12T15:51:56.643Z [INFO]  agent.server: Handled event for server in area: event=member-update server=consul-server-2.acuitydc1 area=wan
2021-09-12T15:52:03.676Z [WARN]  agent: Coordinate update blocked by ACLs: accessorID=00000000-0000-0000-0000-000000000002
2021-09-12T15:52:29.073Z [WARN]  agent: Coordinate update blocked by ACLs: accessorID=00000000-0000-0000-0000-000000000002
2021-09-12T15:52:58.351Z [WARN]  agent: Coordinate update blocked by ACLs: accessorID=00000000-0000-0000-0000-000000000002
2021-09-12T15:53:05.044Z [WARN]  agent: grpc: addrConn.createTransport failed to connect to {172.29.153.17:8300 0 consul-server-1.acuitydc1 <nil>}. Err :connection error: desc = "transport: Error while dialing dial tcp 172.29.153.17:8300: operation was canceled". Reconnecting...

What am I missing in my config that this deployment is not successful?

Hey @HarishankarYellaprag

After a brief look, this looks like a networking issue because there an i/o timeout error in consul-server-acl-init. Could you double check that the pod running that job can connect to server pods over pod IPs?