When HVAC professionals talk about AC size, they are not referring to the physical dimensions of the equipment. They are referring to cooling capacity: the amount of heat a system can remove from a home per hour. Cooling capacity is measured in British thermal units (BTUs) or, more commonly in residential applications, tons. One ton of cooling capacity equals 12,000 BTUs per hour.
A system that is too small cannot remove heat fast enough to meet demand. A system that is too large removes heat so quickly that it shuts off before completing a full cooling cycle. Both create problems, and the problems look different enough that they can be easy to misread.
Sizing an AC system is determined by a Manual J load calculation, an engineering assessment that goes well beyond square footage. Ceiling height, window placement, insulation quality, local climate, and sun exposure all factor in. Two homes with identical footprints can require noticeably different cooling capacity based on how they are built and where they sit.