Find the main supply duct. This is the large duct leading away from your HVAC unit to supply the building.
Measure the width and height of the heating and cooling system's main supply duct.
Multiply the width by the height to determine the area of the main supply. If your main supply duct measured 10 inches by 24 inches, the area would be 240 inches.
Your air return duct should have an area of at least that size. A larger return -- for example to match a standard grate size -- is no problem. Smaller returns, however, can make your system operate below its capacity.