Help with water heater selection please.

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rwagz

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I'm researching my replacement because I am on borrowed time here! Many search hits bring me here. Thanks Terry! I'd appreciate some help figuring out my replacement before I'm doing this under duress.

I have a 21 year old AO Smith FPSE 50 236 power vent water heater. It had been in service for seven years when I bought the house. I will keep it going as long as the tank remains viable. For maintenance I replaced the T&P valve and anode in the last few years (which is neglect.) For repair - I replaced the ignitor, the pilot control and the vent-proving pressure switch. After 20 years of heat cycling, a printed circuit board trace cracked on the pilot control. I was able to make this honeywell controller work after a long long study of the wiring diagrams. I'm replacing the dip tube tomorrow.

My research tells me a lot has changed in the last 20 years. I wish I could find a new old stock FPSE 50 236! There is no shortage of complaints on the internet. AO Smith is not a no-brainer brand choice due to reports of their moving manufacturing to a cheap labor country with a resulting decline in quality. The ease of internet complaints make it easy to find problems but difficult to find context such as overall number of manufactured units and a relative failure rate. Manufacturer consolidation and re-badging to lower price points with cheaper components add confusion. Most of the epic brand comparison threads are several years old.

Existing specification is adequate if not a little less than what we need. 46000BTU, 50gal, recovery 48gal/hr, power vent. Replacement models cost between $1,000 to $2,100. I don't need a low-emission model. I'm willing to spend higher for higher efficiency and/or expected longevity. I can go for a cheaper unit with a lower warranty and add my own anode to the hot port.

Replacements seem to be a touch lower in BTU/recovery specs. I am also considering getting a water heater booster. Thoughts?

Manufacturer short list is AO Smith and Rheem. I could get a Bradford White but am avoiding it because DIY and the expected hassle when a non-professional (me) tries to make a warranty claim.

What are your thoughts? Other brands? What about the variation in quality within the same brand? Should I get a booster?
 
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