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When synching FO with PC in a raid format I am getting my doubts, that my orb actually connects with more than the boss. The orb starts to slow down as soon as it connects with the boss hitbox and most of the time the duration will be over before the orb really touches the boss. Usually I placed my PC just on top of the boss, but maybe I should try to draw the PC back more towards myself/frozen orb.

The hitboxes are huge so where is PC ideally placed? How far can I go and still split? Maybe going into melee range to place the orb is the way to go?

Splitting Ice has a really short and iffy range, so whenever possible you should place PC smack bang in the middle of the Boss. Right under their torso. Frozen Orbs range extends beyond what the visual indicates. If it hits the boss, then it will also hit the Prismatic Crystal that is in the middle of the boss, as far as I understand.

Just place a crystal and shoot an orb on it. The first hit will slow the orb down so you will see how close the orb actually needs to be in order to hit. If I smack the crystal into the middle of the boss i doubt I will even hit the pc. Although in the pull itself it is hard to check, but it just seems to be mandatory for some bosses to place the orb in melee range.

I do think it hits the PC - it should - but even if it doesn't, it's better to place it directly on top of the boss because of Splitting Ice.