opt(chat): Enhance error handling for chat.send timeouts and improve logging in gateway RPC calls (#788)

electron/main/ipc-handlers.ts

@@ -1152,6 +1152,7 @@ function registerGatewayHandlers(
       const result = await gatewayManager.rpc(method, params, timeoutMs);
       return { success: true, result };
     } catch (error) {
+      logger.warn(`[gateway:rpc] ${method} failed (timeoutMs=${timeoutMs ?? 30000}): ${String(error)}`);
       return { success: false, error: String(error) };
     }
   });

src/stores/chat.ts

@@ -956,6 +956,15 @@ function upsertToolStatuses(current: ToolStatus[], updates: ToolStatus[]): ToolS
   return next;
 }
 
+/**
+ * Only treat an explicit chat.send ack timeout as recoverable.
+ * Gateway stopped / Gateway not connected are hard failures that
+ * should still terminate the send immediately.
+ */
+function isRecoverableChatSendTimeout(error: string): boolean {
+  return error.includes('RPC timeout: chat.send');
+}
+
 function collectToolUpdates(message: unknown, eventState: string): ToolStatus[] {
   const updates: ToolStatus[] = [];
   const toolResultUpdate = extractToolResultUpdate(message, eventState);
@@ -1675,14 +1684,26 @@ export const useChatStore = create<ChatState>((set, get) => ({
       console.log(`[sendMessage] RPC result: success=${result.success}, runId=${result.result?.runId || 'none'}`);
 
       if (!result.success) {
+        const errorMsg = result.error || 'Failed to send message';
+        if (isRecoverableChatSendTimeout(errorMsg)) {
+          console.warn(`[sendMessage] Recoverable chat.send timeout, keeping poll alive: ${errorMsg}`);
+          set({ error: errorMsg });
+        } else {
           clearHistoryPoll();
-        set({ error: result.error || 'Failed to send message', sending: false });
+          set({ error: errorMsg, sending: false });
+        }
       } else if (result.result?.runId) {
         set({ activeRunId: result.result.runId });
       }
     } catch (err) {
+      const errStr = String(err);
+      if (isRecoverableChatSendTimeout(errStr)) {
+        console.warn(`[sendMessage] Recoverable chat.send timeout, keeping poll alive: ${errStr}`);
+        set({ error: errStr });
+      } else {
         clearHistoryPoll();
-      set({ error: String(err), sending: false });
+        set({ error: errStr, sending: false });
+      }
     }
   },
 
@@ -1761,11 +1782,11 @@ export const useChatStore = create<ChatState>((set, get) => ({
         break;
       }
       case 'delta': {
-        // If we're receiving new deltas, the Gateway has recovered from any
+        // Clear any stale error (including RPC timeout) when new data arrives.
-        // prior error — cancel the error finalization timer and clear the
-        // stale error banner so the user sees the live stream again.
         if (_errorRecoveryTimer) {
           clearErrorRecoveryTimer();
+        }
+        if (get().error) {
           set({ error: null });
         }
         const updates = collectToolUpdates(event.message, resolvedState);

src/stores/gateway.ts

@@ -177,6 +177,7 @@ function handleGatewayNotification(notification: { method?: string; params?: Rec
             activeRunId: null,
             pendingFinal: false,
             lastUserMessageAt: null,
+            error: null,
           });
         }
       })