First of all, let me state that I've started looking into OpsWorks just about 2 weeks ago. So I'm far from being a pro. But here's my understanding how it works:
We need to differentiate between instances that are instance store backed, and instances that are EBS backed:
- The instance store disappears together with the instance once it's shut down. Therefore, bringing it up again, starts from zero. It has to download the latest app again and will deploy that.
- For EBS backed instances the deployed code remains intact (persisted) exceeding the lifetime of the instance to which it is attached. Therefore, bringing an EBS backed instance back to life, will not update your app automatically. The old version remains deployed.
So your first decision needs to be what instance type to use. It is generally a good idea to have the same version of your app on all instances. Therefore I would suggest going with EBS-backed instances which will not automatically deploy new versions when booting up. In this case, deploying a new version would mean to bring up brand new instances that will be running the new code automatically (as they are new), and then destroying the old instances. You will have a very short time during which old and new code will run side by side.
However, if you prefer to have always the very latest version deployed and can afford risking discrepancies between the individual instances for an extended period of time (e.g. having different app versions deployed depending on when an instance was originally started), then instance store backed might be your choice. Every time a new instance spins up, the latest and greatest code will be deployed. If you want to update existing ones, just bring up new instances instead and kill the existing ones.
Both strategies should give you the desired effect of zero downtime. The difference is on when and how the latest code is being deployed. Combine this with HAProxy to have better control which servers will be used. You can gradually move traffic from old instances to new instances for example.