The RBF size is different because if you right click on the .rbf in the Windows OS you will see that the actual file size is different than the "size on disk". The size on disk is just the size that it takes on the disk itself but the true file size of the rbf file is equal to the size specified in the device handbook in bytes.
Please take note of the way Windows OS calculates the file sizes when comparing file sizes.
For example, an EP3C120 device should have a 3,571,462 byte file size, but the .rbf is shown as 3,571,712 bytes in the Windows OS file properties.