BattWiseR-value targets by climate zone, and what it takes to hit them.

HVAC size for 800 ft² in Zone 6 with a good envelope and 8 ft ceilings

Cooling
1tons
11,520 BTU/h for 800 ft² in Zone 6 — good envelope, 8 ft ceilings
Equipment size by envelope quality1 tongood envelopeas it is now1 tonvery good envelopesealed and insulatedalready at the practical floor for this area and climate
Cooling load11,520BTU/h
Nearest size soldair conditioners come in half-ton steps1 ton12,000 BTU/h
Heating loadfurnace output, not input — divide by AFUE for input rating35,200BTU/h
ClimateMinneapolis, Burlington, HelenaZone 6 — 18 / 55 BTU per ft²
Envelopewell insulated and air sealed, modern windowsGood (× 0.8)
Ceiling adjustment8 ft against the 8 ft baseline× 1
If the envelope were very goodalready there1 ton
Conditioned area
800 ft²
Climate zone
Zone 6
Envelope
good
Ceiling height
8 ft

The common mistake is buying too much

Not too little. An oversized air conditioner cools the air quickly and shuts off before it has run long enough to pull moisture out, leaving a house that is cold and clammy. It short-cycles, which wears the compressor, and it costs more to buy and more to run.

800 ft² in Zone 6 with a good envelope and 8 ft ceilings works out to about 11,520 BTU/h of cooling — 1 ton, since units are sold in half-ton steps — and 35,200 BTU/h of heating output.

If a contractor quotes noticeably more than this, ask which load calculation it came from.

Insulation buys you a smaller machine

This is the part that never appears in insulation payback figures, and it is cash on install day rather than spread over a decade.

The same house with a very good envelope would need 1 ton instead of 1. Equipment is priced per ton. Sealing and insulating before replacing a system is one of the few home improvements that pays part of its own cost immediately.

This is not a Manual J, and it does not pretend to be

A real load calculation works from every wall, window and door individually, their orientation, occupancy, internal gains and measured air leakage. Many jurisdictions require one on a permit for equipment replacement, and a contractor unwilling to produce one is telling you something useful.

Use this as a sanity check on a quote, not as a specification.

Output, not input

A furnace rated 80,000 BTU input at 80% efficiency delivers 64,000. The 35,200 figure above is delivered output — check which one a quote is using before comparing two of them.

Ducts are the other half

A correctly sized unit on undersized or leaky ductwork performs like an undersized one, and adding tonnage does not fix it. If the existing ducts are being reused, they deserve the same scrutiny as the box.

Notes

  • **The common mistake is oversizing, not undersizing.** An air conditioner that is too large pulls the temperature down fast and shuts off before it has run long enough to remove moisture. The result is a house that is cold and clammy, a compressor that short-cycles itself to an early death, and higher bills than the right-sized unit. If a contractor quotes noticeably more tonnage than this, ask what load calculation it came from.
  • At this envelope quality the load is already close to the floor for this floor area and climate. Further insulation still saves fuel, but it will not drop you another equipment size.
  • **This is not a Manual J.** A real load calculation works from every wall, window and door, its orientation, the number of occupants, internal gains and measured air leakage. Many jurisdictions require one on a permit for equipment replacement, and any contractor unwilling to produce one is telling you something. Treat this figure as a sanity check on the quote you are given, not as a specification.
  • Heating output is not furnace input. A furnace rated 80,000 BTU input at 80% AFUE delivers 64,000. Size on delivered output — 35,200 BTU/h here — and check which number the quote is using.
  • Ductwork is the other half, and it is where most systems actually fail. A correctly sized unit on undersized or leaky ducts performs like an undersized one, and no amount of extra tonnage fixes it.

Nearby sizes

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