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,

Sorry for the delay with this issue. Please check the PRs below for the FPROTECT issue:

https://github.com/nrfconnect/sdk-mcuboot/pull/576 

https://github.com/nrfconnect/sdk-nrf/pull/25655 

Kind Regards,

Abhijith

[Erlend Isachsen]

After a while I was finally able to test the fix in some of the newer SDK versions, and I'm now able to build with sysbuild+MCUboot+TFM / non-secure variant with both nRF54l15 DK and our custom boards. However, I only managed to get it working with the partition manager, which since the creation of this thread has been marked as depreciated. As soon as I tried to switch to DTS-style partitioning (nRF Connect SDK 3.3.1) I encountered problems again, for example:

In file included from C:/ncs/v3.3.1/zephyr/include/zephyr/toolchain.h:52,
                 from C:/ncs/v3.3.1/zephyr/include/zephyr/kernel_includes.h:23,
                 from C:/ncs/v3.3.1/zephyr/include/zephyr/kernel.h:17,
                 from C:/ncs/v3.3.1/bootloader/mcuboot/boot/zephyr/main.c:22:
C:/ncs/v3.3.1/bootloader/mcuboot/boot/zephyr/main.c: In function 'main':
C:/ncs/v3.3.1/zephyr/include/zephyr/toolchain/gcc.h:87:36: error: static assertion failed: "Can not FPROTECT region that big"
   87 | #define BUILD_ASSERT(EXPR, MSG...) _Static_assert((EXPR), "" MSG)
      |                                    ^~~~~~~~~~~~~~
C:/ncs/v3.3.1/bootloader/mcuboot/boot/zephyr/main.c:951:5: note: in expansion of macro 'BUILD_ASSERT'
  951 |     BUILD_ASSERT(FPROTECT_REGION_SIZE <= (62 * 1024), "Can not FPROTECT region that big");

Where again the 62KiB limitation appears (close to the 64KiB / 0x10000 limitation some have reported previously). This was for my custom board/application, but if I modify the "with_mcuboot" sample to use the dts partition manager with nRF54L15 DK ns I get another error:

Generating files from C:/ncs/v3.3.1/zephyr/samples/sysbuild/with_mcuboot/build/with_mcuboot/zephyr/zephyr.elf for board: nrf54l15dk/nrf54l15/cpuapp/ns
Usage: imgtool.py sign [OPTIONS] INFILE OUTFILE
Try 'imgtool.py sign -h' for help.

Error: Image size (0x91580) + trailer (0x20) exceeds requested size 0x80000
image.py: sign the digest
ninja: build stopped: subcommand failed.

So before marking this problem as resolved, it would be nice to be able to build my applications or even a sample application with the latest/current recommended configuration for the nRF54L15:

MCUboot+sysbuild+ns-variant+dts-style partitioning.

Or, even better:
NSIB+MCUboot+sysbuild+ns-variant+dts-style partitioning+KMU.

Which seems to be the latest recommendation based on your previous answer and this guide.

Any suggestions?

[Simon D-M]

Hi,

(I'm taking this case from Abhijith, so if I'm missing some context, feel free to make me aware of it.)

I would recommend you to follow this guide (link) on migrating from partition manager to devicetree partitioning.

For the KMU we have extensive documentation on this (link). You should be able to find all the information you need about it there.

Then, for the NSIB, we have a sample (link) that has some documentation on it, also shows how to use it. And here are proper guides to use NSIB with MCUBoot (link).

I believe that with all of this you should already be able to go quite far.

If you have any more questions, feel free to ask them.

Best regards,

Simon

[Erlend Isachsen]

Hi, thank you for the suggestions.

Some context:

The original ticket: Enabling TFM with MCUboot on the nRF54L15 ran into problems with FPROTECT, making the image un-bootable due to FPROTECT size limitations. This was patched in the PR Abhijith linked, and I was happy to see that it was resolved when testing the newer SDKs. However, when I tried to migrate to dts-style partitions following the guide you linked, I ran into the same problem with FPROTECT again. This makes me believe the bug was only patched with the partition manager.

Can you verify if this is the case?