MCUBoot+sysbuild+ns-variant: E: Protect mcuboot flash failed, cancel startup.

[Erlend Isachsen]

Hi.

Goal
I am creating a new application for the nRF54l15 and want to follow the latest recommendations for project configuration. I need to do DFU over BLE, so I'm trying to add MCUBoot in the chain-of-trust regime, using sysbuild. To get there, I used the zephyr/samples/sysbuild/with_mcuboot as a starting point.

Problem
The sample in question does not explicitly support any of the nordic boards with secure/non-secure regime, and I haven't found any samples that combine all these criteria. So I have tried to build the zephyr/sysbuild/with_mcuboot sample for nrf54l15dk/nrf54l15/ns. After erase+flash to my nRF54l15-PDK, I get the following error:

*** Booting MCUboot v2.1.0-dev-2b69d93e75bc ***
*** Using nRF Connect SDK v3.1.0-6c6e5b32496e ***
*** Using Zephyr OS v4.1.99-1612683d4010 ***
E: Protect mcuboot flash failed, cancel startup.

How to recreate
Open zephyr/sysbuild/with_mcuboot and build for zephyr/sysbuild/with_mcuboot sample for nrf54l15dk/nrf54l15/ns. My first build failed, but after doing a pristine build it built successfully and I was able to flash (VSCode build output is attached). Finally, flash to the DK and it should produce the error message shown above.

My setup
Support information is attached. I'm using SDK and toolchain version 3.1.0 with VSCode for windows 10, and nRF54L15-PDK (0.8.1, 2024.38).

Solutions?
I don't have to be able to run this exact sample, but what is causing this error and how do I best resolve it?

vscode_build_log.txt 

Fullscreen nrf-connect-support-20250818091511.json Download

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// If you do not want others to see this information, make sure to remove it before sharing the data.

// For help and support, visit Nordic Semiconductor's DevZone at https://devzone.nordicsemi.com/.

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[Menon]

Hello,

I understand your concern, and I completely agree that this needs to be fixed. I am closely following the issue and will update you as soon as it is resolved. I’m sorry for the delay and apologize for the inconvenience this has caused.

Kind regards,
Abhijith

[Yannick Bus]

Hello,

We are having the same issue as the gentleman above, enabling FProtect for us seems to result in "<err> mcuboot: Protect mcuboot flash failed, cancel startup." However we are allready on a non-ns build.

Have there been any updates or workarounds for this issue found in the meantime?

Kind Regards,
Yannick Bus

[Erlend Isachsen]

Hi. Maybe I can provide some help. If FProtect fails it is likely that your MCUBoot primary partition has a too big offset from the start of the flash. On ns-builds, this will typically be caused by TFM partitions as discussed above. Since you are on a non-ns build, it means something else is taking up that space. For instance, I wouldn't be surprised if this happens when using MCUBoot as a second stage bootloader.

If you don't need flash protection you can use CONFIG_FPROTECT=n (in sysbuild/mcuboot.conf) to disable it as mentioned, although I would not recommend this as it increases the chance of bugs related to flash-writes (FOTA etc.) to brick your device.

If you need flash protection it would be useful if you can share your pm_static.yml if you have one, or build/partitions.yml. In the latter file, you can check which partitions are before mcuboot_primary. mcuboot_primary address needs to be before 0x10000 on nRF54L15.

If I'm not mistaken, I believe MCUBoot simply looks for the begining of mcuboot_primary, and tries to protect everything before it (including mcuboot itself), and the maximum fprotect size is 64 kiB (0x10000).

[Yannick Bus]

Hello,

Our pm_static.yml has only a single entry:

mcuboot:
  address: 0x00000000
  size:    0x00018000

as far as i can see from the generated partitions.yml there isnt anything too crazy:

mcuboot:
  address: 0x0
  end_address: 0x18000
  region: flash_primary
  size: 0x18000
mcuboot_pad:
  address: 0x18000
  end_address: 0x18800
  placement:
    align:
      start: 0x1000
    before:
    - mcuboot_primary_app
  region: flash_primary
  size: 0x800
mcuboot_primary:
  address: 0x18000
  end_address: 0x165000
  orig_span: &id001
  - mcuboot_pad
  - app
  region: flash_primary
  size: 0x14d000
  span: *id001
mcuboot_primary_app:
  address: 0x18800
  end_address: 0x165000
  orig_span: &id002
  - app
  region: flash_primary
  size: 0x14c800
  span: *id002
mcuboot_secondary:
  address: 0x0
  device: DT_CHOSEN(nordic_pm_ext_flash)
  end_address: 0x14d000
  placement:
    align:
      start: 0x4
  region: external_flash
  share_size:
  - mcuboot_primary
  size: 0x14d000

The only thing i can think of is that we are using an external flash chip for the mcuboot_secondary?

Thank you for your reply!

[Erlend Isachsen]

Hi.

The size of MCUBoot alone is what causing the issue in your case, 96 kiB > 64 kiB. Are you using all that space, or can you reduce it?

I usually find 0xc000 (48 kiB) to be sufficient for mcuboot, and leaves room for debug and logging. If that's sufficient for you, I would suggest editing pm_static.yml like so:

mcuboot:
  address: 0x00000000
  size:    0x000c000

Setting size to 0x10000 might work as well, although I'm not sure as it sits right at that 64 kiB limit.

Since that is all you have in your pm_static.yml, the automatic partition manager should resolve the rest of the partitions as well.