Is the PR-5400 the largest prime gas generator Gillette offers?

Yes — the PR-5400 at 540 kW is Gillette's largest prime-rated natural gas generator. It uses the same PSI 31.8L V12 as the SP-6500 standby (650 kW). The PR-5400 also has LPG capability at a reduced output (the spec sheet lists both NG and LPG fuel consumption), making it one of the few prime-rated units with dual-fuel capability at this power class.

What fuel consumption at 540 kW prime?

5,797 ft3/hr NG at full load. At 75%: 4,450 ft3/hr. At 50%: 3,254 ft3/hr. This is nearly 5.8 MMBTU/hr of continuous gas demand — requires a dedicated high-capacity gas utility connection.

What is the standby-to-prime derating?

The SP-6500 (standby) rates this same engine at 650 kW / 966 bhp. The PR-5400 (prime) rates it at 540 kW / 805 bhp — a 17% derating for unlimited continuous hours. This is a more moderate derating than the smaller models because the 31.8L V12 has substantial displacement headroom.

Gillette · PR Series (Prime Gas)

Gillette PR-5400

540 kW standby · Natural Gas · Liquid-cooled

540 kW prime-rated natural gas generator. PSI 31.8L V12 turbocharged, Stamford HCI534 alternator, DSE 7420. Continuous duty, 3-phase only. Gillette's largest prime gas unit.

Standby power: 540 kW / 540 kW prime
Voltage options: 120/208V, 120/240V, 277/480V, 346/600V
Frequency / Phase: 60 Hz · 3-phase
Engine: PSI 31.8L V12 TCAC · 31.8L
EPA / Emissions: EPA Stationary Spark Ignition
Alternator: Stamford HCI534E-311

prime-powerremote-siteminingManufacturingoff-gridCommercial

Overview#

The Gillette PR-5400 is a 540-kilowatt prime-rated natural gas generator — Gillette's largest prime gas unit. PSI's 31.8L V12 at 805 bhp for continuous duty, the same engine as the SP-6500 (650 kW standby). Stamford HCI534 alternator, DSE 7420 controller, three-phase only.

At 540 kW continuous natural gas, this serves large industrial operations, mining sites, and remote facilities requiring utility-grade prime power without grid dependency.

The PSI 31.8L at continuous duty#

The 31.8L V12 runs at 805 bhp prime vs. 966 bhp standby — a comfortable 17% derating. This large displacement provides excellent thermal margin for sustained 24/7 operation. The 6-filter oil system (119 qt with filters) requires planned logistics for service events.

Our service experience#

At 540 kW prime with 12 cylinders, this is the most complex gas generator service we perform. Each 250-hour oil service and 1000-hour ignition service is a planned multi-technician event. We recommend 24/7 remote monitoring via the DSE 7420's Modbus interface to detect developing issues before they cause unplanned shutdowns.

Engineering specifications

Physical

Length: 186 in
Width: 92 in
Height: 98 in
Wet weight: 15,950 lb

Acoustic

Sound @ 7m, full load: 86 dBA
Enclosure: Sound-attenuated

Fuel system & runtime

BTU/hr @ full load: 5,797,000

Photos

Documents & downloads

Spec sheets & manuals

Spec sheet (datasheet)

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Estimate runtime for the Gillette PR-5400

Adjust load percent and tank size to estimate runtime. Pre-filled with this model's spec where available.

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Generator size

Fuel

Load

Fuel demand at 75% load

5,670,000 BTU/hr≈ 5670.0 cf/min @ 1,000 BTU/cf

On utility natural gas the runtime is generally unlimited provided the supply line and meter can deliver this BTU/hr at the engine's required inlet pressure (typically 5–14" WC residential, up to 5 psi commercial). Confirm against the OEM's published fuel-pressure spec.

Service intervals

Manufacturer-recommended intervals for the Gillette PR-5400 under standby duty. Field intervals may differ based on load profile, ambient conditions, and fuel quality.

Oil & filter: Every 250 hours or 6 months
Coolant change: Every 4000 hours
Air filter: Every 500 hours
Spark plugs: Every 1000 hours
Major overhaul: ≈ 15,000 hours
Load bank test: Every 12 months

Common failure modes

What we've seen fail on this platform. Use as a service-planning reference, not a diagnostic — actual failure modes depend heavily on duty cycle and maintenance history.

Component	Symptom	Typical hours	Severity
Turbocharger	Power loss from continuous high-output duty	10,000+	moderate
Spark plugs / ignition	Misfire, rough running under sustained load	1,000+	moderate
Oil degradation	Accelerated valve train wear from continuous duty	250+	minor

Frequently Asked Questions

Is the PR-5400 the largest prime gas generator Gillette offers?: Yes — the PR-5400 at 540 kW is Gillette's largest prime-rated natural gas generator. It uses the same PSI 31.8L V12 as the SP-6500 standby (650 kW). The PR-5400 also has LPG capability at a reduced output (the spec sheet lists both NG and LPG fuel consumption), making it one of the few prime-rated units with dual-fuel capability at this power class.
What fuel consumption at 540 kW prime?: 5,797 ft3/hr NG at full load. At 75%: 4,450 ft3/hr. At 50%: 3,254 ft3/hr. This is nearly 5.8 MMBTU/hr of continuous gas demand — requires a dedicated high-capacity gas utility connection.
What is the standby-to-prime derating?: The SP-6500 (standby) rates this same engine at 650 kW / 966 bhp. The PR-5400 (prime) rates it at 540 kW / 805 bhp — a 17% derating for unlimited continuous hours. This is a more moderate derating than the smaller models because the 31.8L V12 has substantial displacement headroom.

Compatible equipment

Controllers

DSE 7420 MkIIControllers

Transfer switches

More in the PR Series (Prime Gas)

80–540 kW natural gas prime power on PSI engines — continuous duty for remote sites, mining, and off-grid operations.

View all 7models in this series →

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