fix: SIP connect hang - arm timeout before await connect

src/hooks/use-telnyx.ts

@@ -82,6 +82,7 @@ export function useTelnyx(): UseTelnyxReturn {
   const callRef = useRef<any>(null)
   const durationIntervalRef = useRef<ReturnType<typeof setInterval> | null>(null)
   const callStartTimeRef = useRef<number | null>(null)
+  const connectStartTimeRef = useRef<number>(0)
 
   const [connectionStatus, setConnectionStatus] = useState<ConnectionStatus>('disconnected')
   const [isRegistered, setIsRegistered] = useState(false)
@@ -622,23 +623,29 @@ export function useTelnyx(): UseTelnyxReturn {
         })
 
         clientRef.current = client
-        await client.connect()
+        connectStartTimeRef.current = Date.now()
 
-        // Safety net: if telnyx.ready doesn't fire within REGISTRATION_TIMEOUT_MS,
-        // reset status from 'connecting' to 'disconnected' so periodic checks
-        // can retry. Without this, a failed registration leaves status stuck on
-        // 'connecting' and all ensureRegistered() calls bail early.
+        // Arm timeout BEFORE awaiting connect to avoid hangs where connect() never resolves.
         if (registrationTimeoutRef.current) {
           clearTimeout(registrationTimeoutRef.current)
         }
-        registrationTimeoutRef.current = setTimeout(() => {
-          if (destroyed) return
-          if (connectionStatusRef.current === 'connecting') {
-            console.warn('[useTelnyx] Registration timeout - telnyx.ready not received within', REGISTRATION_TIMEOUT_MS, 'ms, resetting to disconnected')
+        const timeoutPromise = new Promise<never>((_, reject) => {
+          registrationTimeoutRef.current = setTimeout(() => {
+            if (destroyed) return
+
+            console.warn(
+              '[useTelnyx] SIP connect timeout - connect/ready not received within',
+              REGISTRATION_TIMEOUT_MS,
+              'ms'
+            )
             markInitialized()
-            setConnectionStatus('disconnected')
-          }
-        }, REGISTRATION_TIMEOUT_MS)
+            setConnectionStatus('error')
+            setRegistrationState(false)
+            reject(new Error('SIP connect timeout'))
+          }, REGISTRATION_TIMEOUT_MS)
+        })
+
+        await Promise.race([client.connect(), timeoutPromise])
       } catch (err) {
         console.error('[useTelnyx] Failed to initialize:', err)
         if (!destroyed) setConnectionStatus('error')
@@ -734,7 +741,16 @@ export function useTelnyx(): UseTelnyxReturn {
 
     async function ensureRegistered(reason: string) {
       if (destroyed || isInitializingRef.current) return false
-      if (connectionStatusRef.current === 'connecting') return false
+      if (connectionStatusRef.current === 'connecting') {
+        const elapsed = Date.now() - connectStartTimeRef.current
+        if (connectStartTimeRef.current > 0 && elapsed > REGISTRATION_TIMEOUT_MS) {
+          console.warn(
+            `[useTelnyx] ensureRegistered detected stuck connecting (${reason}) after ${elapsed}ms - triggering recovery`
+          )
+          await triggerManualReconnect('connect-timeout')
+        }
+        return false
+      }
 
       const activeClient = clientRef.current
       if (!activeClient) {