SYCON BoB
SYCON BoB – TÜV-certified online analyzer for steam boiler systems, 72h BOB operation according to WÜV 100, RS485 Modbus RTU, 4 relays, 4-20 mA
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SYCON BoB – TÜV-certified analyzer for steam boiler systems
Why is certified hardness monitoring required in the boiler house?
Steam boiler systems place the highest demands on the quality of the feed water. Even the smallest amounts of residual hardness can lead to limescale deposits on the heating surfaces – resulting in overheating, loss of performance and, in the worst case, boiler damage. VdTÜV Code of Practice WÜV 100 therefore requires continuous, automated monitoring of water hardness using certified devices – including the option of 72-hour unattended operation (BOB).
What is the SYCON BoB?
The SYCON BoB from RLS Wacon is a fully automatic online analyzer for monitoring the residual hardness in boiler feed water and returning condensate. It is certified in accordance with VdTÜV data sheet WÜV 100 and therefore fulfills the requirement for operation without supervision (BOB) for 72 hours.
The device is based on the proven SYCON platform, but is specially optimized for use in steam boilers: Pre-configured relays, an access code to protect against incorrect parameterization, a BOB probe for level monitoring of the Reagent and a shortened maintenance interval ensure maximum operational reliability.
How does the SYCON BoB work?
The SYCON BoB works according to the colorimetric titration method. A water sample is automatically fed into the measuring chamber and the Reagent (H25-0.05 or H25-0.1) is added step by step. An optical sensor detects the color change and calculates the residual hardness of the water.
The integrated BOB sensor continuously monitors the fill level of the indicator bottle. As soon as the remaining content is sufficient for less than 72 hours of operation (approx. 12 % fill level), a BOB message is issued via relay 2 and the display. This ensures that the indicator supply is replenished in good time.
The analysis time is approx. 3 minutes with an indicator consumption of only 0.05 ml per analysis. Up to 10,000 analyses are possible with a 500 ml bottle.
Special features compared to the other SYCON models
| Feature | SYCON BoB | SYCON 2702/2802 |
|---|---|---|
| TÜV certification (WÜV 100) | Yes | – |
| BOB probe (72h level monitoring) | Yes | – |
| Access code | Yes | – |
| Preconfigured relays | Yes (standardized wiring) | Freely configurable |
| Indicator selection | H25-0.05 or H25-0.1 (fixed) | All H25/C25 Reagents |
| Maintenance interval | 12 months / 15,000 analyses | 24 months / 30,000 analyses |
| External analysis start | – (not possible) | Yes |
Advantages of the SYCON BoB
- TÜV-certified according to VdTÜV data sheet WÜV 100
Meets the legal requirements for the unattended operation of steam boiler systems
- 72-hour BOB operation with fill level monitoring
The BOB probe signals in good time when the indicator supply needs to be replenished – can be extended to up to 144 hours with a longer measuring interval
- Access code to protect against incorrect parameterization
Locks access to critical settings during unattended operation
- Preconfigured relays for standardized installation
Limit value, BOB message, device fault, analysis active – Terminal diagram can be created in advance
- RS485 interface with Modbus RTU
Integration into the boiler control system and higher-level control systems
- Analog output 0/4-20 mA
Direct transmission of measured values to the system controller
- Robust housing (IP54, IK08)
Suitable for the harsh environmental conditions in the boiler house
- Self-calibrating full color sensor
No manual calibration – automatic compensation for ambient light, contamination and turbidity
- Very low indicator consumption
0.05 ml per analysis – up to 10,000 analyses per 500 ml bottle
Field of application
The SYCON BoB is specially designed for use in steam boilers:
| Area of application | Description |
|---|---|
| Steam boiler systems | Continuous monitoring of the residual hardness in the boiler feed water – TÜV-certified for 72-hour operation without supervision in accordance with WÜV 100 |
| Condensate return | Monitoring the returning condensate for hardness breakthroughs – an increase in hardness indicates leaks in the heat exchanger |
| Full softening for steam generators | Monitoring of the softening system in the sensitive range up to 0.05 °dH – the limit value is adapted to the strict requirements in the steam boiler sector |
Requirements for the sample water
| Parameters | Requirement |
|---|---|
| pH value | 4-10 |
| Iron (Fe) | < 3 ppm |
| Copper (Cu) | < 0.2 ppm |
| Aluminum (Al) | < 0.1 ppm |
| Manganese (Mn) | < 0.2 ppm |
| Acid capacity KS 4.3 | < 5 mmol/l |
| Characteristics | Clear, colorless, free of solids, free of gas bubbles |
Maintenance
The SYCON BoB is subject to a shortened maintenance interval in order to meet the high requirements in the steam boiler sector:
| Interval | Measure |
|---|---|
| Every 6 months | Cleaning the measuring chamber |
| Every 15,000 analyses or 12 months | Installation of the maintenance set: Replacement of the peristaltic pump cassette, seals and agitator blades |
Installation and commissioning
- Mount the device on a dry, easily accessible wall – Use mounting brackets
- Make water connections: Inlet and outlet via 6 mm hose
- Electrical connections: Supply voltage, 4 relay outputs, analog output, RS485, 2 digital inputs
- Insert Reagent (H25-0.05 or H25-0.1), connect BOB probe
- Start the installation wizard – Enter the access code (factory setting: 2802)
- Start the first analysis run and check the measured value
Tip for BOB operation
With an analysis interval of 10 minutes instead of 5 minutes, the BOB period is extended from 72 to 144 hours – with the same indicator quantity. The maximum number of analyses in the BOB period is 864 analyses.
Important notes
- For indoor use and wall mounting only
- Only the Reagents H25-0.05 and H25-0.1 are permitted in the SYCON BoB
- The BOB sensor must be connected correctly before switching on (error E15 if not connected)
- External analysis start is not possible with SYCON BoB
- Free, short drain without back pressure required
- Oxidizing agents (chlorine, ozone) above the drinking water limit values impair the measurement
- Install maintenance set (item no. 33-030099) every 12 months or 15,000 analyzes
- Clean the measuring chamber every 6 months – use SYCON Clean (item no. 30-010900)
Reagents and limit values
| Reagent | Limit value (°dH) | Limit value (mmol/l) | Item no. |
|---|---|---|---|
| H25-0,05 | 0,025 | 0,005 | 32-084125 |
| H25-0.1 (preset) | 0,05 | 0,01 | 32-084135 |
Only these two Reagents are approved for the SYCON BoB.
Specifications at a glance
| Property | Value |
|---|---|
| Measuring principle | Colorimetric titration method |
| Parameters | Residual hardness (total hardness) |
| Certification | VdTÜV leaflet WÜV 100 – Operation without supervision (72 h) |
| Reagent H25-0.05 | Limit value 0.025 °dH / 0.005 mmol/l |
| Reagent H25-0.1 | Limit value 0.05 °dH / 0.01 mmol/l |
| Units | °dH, °f, ppm CaCO₃, mmol/l, °e, °Ж |
| Accuracy | ± 5 % |
| Analysis time | approx. 3 minutes |
| Indicator consumption | approx. 0.05 ml per analysis |
| Analyses per 500 ml bottle | up to 10.000 |
| Water consumption | approx. 1 l per analysis at 2 bar |
| Durability Reagent | at least 2 years (stored at < 25 °C, in the dark) |
BOB operation
| Analysis interval | BOB period |
|---|---|
| 5 minutes (standard) | 72 hours |
| 7 minutes | 96 hours |
| 9 minutes | 120 hours |
| 10 minutes | 144 hours |
At a residual level of approx. 12 % (corresponds to 864 analyses), the BOB probe signals via relay 2 and the display that the Reagent needs to be topped up.
Electrical data
| Property | Value |
|---|---|
| Supply voltage (230 V version) | 100-240 V AC, 50/60 Hz |
| Supply voltage (24 V version) | 21.6-26.4 V AC/DC, 50 Hz |
| Power consumption | 25 VA (operation) / 3.5 VA (standby) |
| Relay 1 | Limit value (programmable) |
| Relay 2 | BOB message (indicator level < 72 h) |
| Relay 3 | Device fault / device switched off |
| Relay 4 | Analysis active / sample pump / cooling water valve |
| Analog output | 0-20 mA or 4-20 mA, resolution < 100 µA, max. 750 Ω Load |
| RS485 interface | Modbus RTU |
| Digital inputs | 2× galvanically isolated – flow monitor, interval reset |
Mechanical data and ambient conditions
| Property | Value |
|---|---|
| Dimensions (W × H × D) | 332 × 345 × 190 mm |
| Weight | approx. 2.7 kg |
| IP protection class | IP54 |
| IK protection class | IK08 |
| Operating temperature | 10-45 °C |
| Storage temperature | 0-45 °C |
| Sample water temperature | 5-40 °C |
| Air humidity | 20-90 % RH (non-condensing) |
| Inlet water pressure | min. 0.5 bar, max. 5 bar (recommended 1-2 bar) |
Reagents
| Reagent | Limit value | Item no. |
|---|---|---|
| H25-0,05 | 0.025 °dH / 0.005 mmol/l | 32-084125 |
| H25-0.1 (factory preset) | 0.05 °dH / 0.01 mmol/l | 32-084135 |
Note: In the SYCON BoB, only the Reagents H25-0.05 and H25-0.1 are approved. These cover the limit values for soft w ater valid in the steam boiler area.
Display and operation
| Property | Value |
|---|---|
| Display | Multicolored graphic display |
| Operation | 8 buttons, access code-protected |
| Languages | German, English, French, Italian, Spanish, Russian, Polish, Dutch, Danish |
| Data memory | SD card (measured value logging and software updates) |
| Access code | Factory setting 2802, can be changed via access.txt on SD card |
Scope of delivery
| Component |
|---|
| 1 × SYCON BoB in housing (configured for selected supply voltage) |
| BOB probe with level monitoring |
| SD card |
| Operating instructions (German or English, depending on order variant) |
Note: A compatible Reagent (H25-0.05 or H25-0.1) is required for operation and must be ordered separately.
Additional information
| Manual | English, German |
|---|
Flyer
Operating instructions
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