Can you explain how Power Factor Correction Capacitors work? If so, it’s the same issue. In the VFD, the DC bus capacitors are storing and releasing the reactive power for the motor, the same as when you have PFC capacitors.
Yes, I was really not considering that it's the dc-link caps in the drive that make this happen with creating VARs, which increases the VA. I had in my mind that VAout couldn't be more than VAin, but that's just not true. I had no problem explaining how this works with PFC caps.
To be honest, this actually turned into a great example of how to better describe reactive power overall, and its impacts, without improperly describing it as some type of inefficiency or going into the math weeds or talking about sine waves, phase angles, or creating and collapsing fields, etc. I will use this in the future.
You can say that the 'grid' had to supply some VARs in order to first charge the caps of the VFD in the first place.
Then when the VFD runs the motor, the grid supplies the drive with real power that is then sent to the motor.
The motor needs VARs-energy for the magnetic rotation as well, and that energy comes from the previously charged VFD's caps and then bounces back and forth between the drive and the motor. It's not really produced or consumed.
We say 'produce' and 'consume' with VARs, but it's really only by convention. Realistically the energy bounces back and forth between two points.
And so in operation the grid and the drive input only sees the real power, but the conductors between the drive and motor see the current from the real power AND the VARs energy.
This shows why we try to mitigate VARs wherever possible because it causes you to increase cable sizes and creates more I^2*R losses between those to points that have the VAR-energy bouncing back and forth
Thanks all