diff --git a/CHANGELOG.md b/CHANGELOG.md
index 90e4841d8..9252176e2 100644
--- a/CHANGELOG.md
+++ b/CHANGELOG.md
@@ -16,6 +16,7 @@
 
 ## Bug fixes
 
+-   Add warning if `ProcessedVariable` is called outisde its interpolation range ([#681](https://github.com/pybamm-team/PyBaMM/pull/681))
 -   Improve the way `ProcessedVariable` objects are created in higher dimensions ([#581](https://github.com/pybamm-team/PyBaMM/pull/581))
 
 # [v0.1.0](https://github.com/pybamm-team/PyBaMM/tree/v0.1.0) - 2019-10-08
diff --git a/pybamm/__init__.py b/pybamm/__init__.py
index 04e9c0840..b6872b51e 100644
--- a/pybamm/__init__.py
+++ b/pybamm/__init__.py
@@ -25,7 +25,7 @@ def _load_version_int():
 __version_int__ = _load_version_int()
 __version__ = ".".join([str(x) for x in __version_int__])
 if sys.version_info[0] < 3:
-    del (x)  # Before Python3, list comprehension iterators leaked
+    del x  # Before Python3, list comprehension iterators leaked
 
 #
 # Expose PyBaMM version
diff --git a/pybamm/logger.py b/pybamm/logger.py
index abee0fd86..27853fb29 100644
--- a/pybamm/logger.py
+++ b/pybamm/logger.py
@@ -3,6 +3,11 @@
 #
 import logging
 
+
+def set_logging_level(level):
+    logger.setLevel(level)
+
+
 format = (
     "%(asctime)s - [%(levelname)s] %(module)s.%(funcName)s(%(lineno)d): "
     + "%(message)s"
@@ -12,7 +17,5 @@ logging.Formatter(datefmt="%Y-%m-%d %H:%M:%S", fmt="%(asctime)s.%(msecs)03d")
 
 # Create a custom logger
 logger = logging.getLogger(__name__)
+set_logging_level("WARNING")
 
-
-def set_logging_level(level):
-    logger.setLevel(level)
diff --git a/pybamm/processed_variable.py b/pybamm/processed_variable.py
index 3a41872e8..a4db4a646 100644
--- a/pybamm/processed_variable.py
+++ b/pybamm/processed_variable.py
@@ -391,19 +391,24 @@ class ProcessedVariable(object):
             fill_value=np.nan,
         )
 
-    def __call__(self, t=None, x=None, r=None, y=None, z=None):
+    def __call__(self, t=None, x=None, r=None, y=None, z=None, warn=True):
         """
         Evaluate the variable at arbitrary t (and x, r, y and/or z), using interpolation
         """
         if self.dimensions == 1:
-            return self._interpolation_function(t)
+            out = self._interpolation_function(t)
         elif self.dimensions == 2:
             if t is None:
-                return self._interpolation_function(y, z)
+                out = self._interpolation_function(y, z)
             else:
-                return self.call_2D(t, x, r, z)
+                out = self.call_2D(t, x, r, z)
         elif self.dimensions == 3:
-            return self.call_3D(t, x, r, y, z)
+            out = self.call_3D(t, x, r, y, z)
+        if warn is True and np.isnan(out).any():
+            pybamm.logger.warning(
+                "Calling variable outside interpolation range (returns 'nan')"
+            )
+        return out
 
     def call_2D(self, t, x, r, z):
         "Evaluate a 2D variable"
diff --git a/pybamm/quick_plot.py b/pybamm/quick_plot.py
index 29caf2b8d..b2470f0ac 100644
--- a/pybamm/quick_plot.py
+++ b/pybamm/quick_plot.py
@@ -320,7 +320,9 @@ class QuickPlot(object):
                             spatial_scale = self.spatial_scales[spatial_var_name]
                         self.plots[key][i][j], = ax.plot(
                             spatial_var_value * spatial_scale,
-                            variable(t, **{spatial_var_name: spatial_var_value}),
+                            variable(
+                                t, **{spatial_var_name: spatial_var_value}, warn=False
+                            ),
                             lw=2,
                             color=colors[i],
                             linestyle=linestyles[j],
@@ -333,7 +335,7 @@ class QuickPlot(object):
                         full_t = self.ts[i]
                         self.plots[key][i][j], = ax.plot(
                             full_t * self.time_scale,
-                            variable(full_t),
+                            variable(full_t, warn=False),
                             lw=2,
                             color=colors[i],
                             linestyle=linestyles[j],
@@ -394,7 +396,9 @@ class QuickPlot(object):
                     for j, variable in enumerate(variable_lists):
                         plot[i][j].set_ydata(
                             variable(
-                                t_dimensionless, **{spatial_var_name: spatial_var_value}
+                                t_dimensionless,
+                                **{spatial_var_name: spatial_var_value},
+                                warn=False
                             )
                         )
             else:

processed variable error when t,x,or r outside of range
make `ProcessedVariable` throw an error if you try and call outside of the solution time and/or space
diff --git a/tests/unit/test_logger.py b/tests/unit/test_logger.py
index 192701f99..effbbf073 100644
--- a/tests/unit/test_logger.py
+++ b/tests/unit/test_logger.py
@@ -8,11 +8,11 @@ import unittest
 class TestLogger(unittest.TestCase):
     def test_logger(self):
         logger = pybamm.logger
-        self.assertEqual(logger.level, 0)
+        self.assertEqual(logger.level, 30)
         pybamm.set_logging_level("INFO")
         self.assertEqual(logger.level, 20)
-        pybamm.set_logging_level("WARNING")
-        self.assertEqual(logger.level, 30)
+        pybamm.set_logging_level("ERROR")
+        self.assertEqual(logger.level, 40)
 
 
 if __name__ == "__main__":
diff --git a/tests/unit/test_processed_variable.py b/tests/unit/test_processed_variable.py
index bd9f9cd0a..a891fdbc6 100644
--- a/tests/unit/test_processed_variable.py
+++ b/tests/unit/test_processed_variable.py
@@ -195,6 +195,11 @@ class TestProcessedVariable(unittest.TestCase):
         np.testing.assert_array_equal(processed_eqn(t_sol), t_sol * y_sol[0])
         np.testing.assert_array_almost_equal(processed_eqn(0.5), 0.5 * 2.5)
 
+        # Suppress warning for this test
+        pybamm.set_logging_level("ERROR")
+        np.testing.assert_array_equal(processed_eqn(2), np.nan)
+        pybamm.set_logging_level("WARNING")
+
     def test_processed_var_2D_interpolation(self):
         t = pybamm.t
         var = pybamm.Variable("var", domain=["negative electrode", "separator"])

pip install -e .[dev,docs]
parse_log_pytest
pytest
flake8 pytest
apt-get update apt-get install -y gcc gfortran libopenblas-dev
3.9
pytest --no-header -rA --tb=line --color=no -p no:cacheprovider -W ignore::DeprecationWarning
alabaster==0.7.16
anyio==4.9.0
anytree==2.12.1
argon2-cffi==23.1.0
argon2-cffi-bindings==21.2.0
arrow==1.3.0
asttokens==3.0.0
async-lru==2.0.5
attrs==25.3.0
autograd==1.7.0
babel==2.17.0
beautifulsoup4==4.13.3
black==25.1.0
bleach==6.2.0
certifi==2025.1.31
cffi==1.17.1
charset-normalizer==3.4.1
click==8.1.8
comm==0.2.2
contourpy==1.3.0
cycler==0.12.1
debugpy==1.8.13
decorator==5.2.1
defusedxml==0.7.1
docutils==0.21.2
exceptiongroup @ file:///croot/exceptiongroup_1706031385326/work
executing==2.2.0
fastjsonschema==2.21.1
flake8==7.2.0
fonttools==4.56.0
fqdn==1.5.1
guzzle_sphinx_theme==0.7.11
h11==0.14.0
httpcore==1.0.7
httpx==0.28.1
idna==3.10
imagesize==1.4.1
importlib_metadata==8.6.1
importlib_resources==6.5.2
iniconfig @ file:///home/linux1/recipes/ci/iniconfig_1610983019677/work
ipykernel==6.29.5
ipython==8.18.1
ipywidgets==8.1.5
isoduration==20.11.0
jedi==0.19.2
Jinja2==3.1.6
json5==0.10.0
jsonpointer==3.0.0
jsonschema==4.23.0
jsonschema-specifications==2024.10.1
jupyter==1.1.1
jupyter-console==6.6.3
jupyter-events==0.12.0
jupyter-lsp==2.2.5
jupyter_client==8.6.3
jupyter_core==5.7.2
jupyter_server==2.15.0
jupyter_server_terminals==0.5.3
jupyterlab==4.3.6
jupyterlab_pygments==0.3.0
jupyterlab_server==2.27.3
jupyterlab_widgets==3.0.13
kiwisolver==1.4.7
MarkupSafe==3.0.2
matplotlib==3.9.4
matplotlib-inline==0.1.7
mccabe==0.7.0
mistune==3.1.3
mypy-extensions==1.0.0
nbclient==0.10.2
nbconvert==7.16.6
nbformat==5.10.4
nest-asyncio==1.6.0
notebook==7.3.3
notebook_shim==0.2.4
numpy==2.0.2
overrides==7.7.0
packaging @ file:///croot/packaging_1734472117206/work
pandas==2.2.3
pandocfilters==1.5.1
parso==0.8.4
pathspec==0.12.1
pexpect==4.9.0
pillow==11.1.0
platformdirs==4.3.7
pluggy @ file:///croot/pluggy_1733169602837/work
prometheus_client==0.21.1
prompt_toolkit==3.0.50
psutil==7.0.0
ptyprocess==0.7.0
pure_eval==0.2.3
-e git+https://github.com/pybamm-team/PyBaMM.git@46b47a12dc7e4c0f16ece8d11b583c5c493392d2#egg=pybamm
pycodestyle==2.13.0
pycparser==2.22
pyflakes==3.3.1
Pygments==2.19.1
pyparsing==3.2.3
pytest @ file:///croot/pytest_1738938843180/work
python-dateutil==2.9.0.post0
python-json-logger==3.3.0
pytz==2025.2
PyYAML==6.0.2
pyzmq==26.3.0
referencing==0.36.2
requests==2.32.3
rfc3339-validator==0.1.4
rfc3986-validator==0.1.1
rpds-py==0.24.0
scikit-fem==10.0.2
scipy==1.13.1
Send2Trash==1.8.3
six==1.17.0
sniffio==1.3.1
snowballstemmer==2.2.0
soupsieve==2.6
Sphinx==7.4.7
sphinxcontrib-applehelp==2.0.0
sphinxcontrib-devhelp==2.0.0
sphinxcontrib-htmlhelp==2.1.0
sphinxcontrib-jsmath==1.0.1
sphinxcontrib-qthelp==2.0.0
sphinxcontrib-serializinghtml==2.0.0
stack-data==0.6.3
terminado==0.18.1
tinycss2==1.4.0
tomli @ file:///opt/conda/conda-bld/tomli_1657175507142/work
tornado==6.4.2
traitlets==5.14.3
types-python-dateutil==2.9.0.20241206
typing_extensions==4.13.0
tzdata==2025.2
uri-template==1.3.0
urllib3==2.3.0
wcwidth==0.2.13
webcolors==24.11.1
webencodings==0.5.1
websocket-client==1.8.0
widgetsnbextension==4.0.13
zipp==3.21.0

name: PyBaMM
channels:
  - defaults
  - https://repo.anaconda.com/pkgs/main
  - https://repo.anaconda.com/pkgs/r
  - conda-forge
dependencies:
  - _libgcc_mutex=0.1=main
  - _openmp_mutex=5.1=1_gnu
  - ca-certificates=2025.2.25=h06a4308_0
  - exceptiongroup=1.2.0=py39h06a4308_0
  - iniconfig=1.1.1=pyhd3eb1b0_0
  - ld_impl_linux-64=2.40=h12ee557_0
  - libffi=3.4.4=h6a678d5_1
  - libgcc-ng=11.2.0=h1234567_1
  - libgomp=11.2.0=h1234567_1
  - libstdcxx-ng=11.2.0=h1234567_1
  - ncurses=6.4=h6a678d5_0
  - openssl=3.0.16=h5eee18b_0
  - packaging=24.2=py39h06a4308_0
  - pip=25.0=py39h06a4308_0
  - pluggy=1.5.0=py39h06a4308_0
  - pytest=8.3.4=py39h06a4308_0
  - python=3.9.21=he870216_1
  - readline=8.2=h5eee18b_0
  - setuptools=75.8.0=py39h06a4308_0
  - sqlite=3.45.3=h5eee18b_0
  - tk=8.6.14=h39e8969_0
  - tomli=2.0.1=py39h06a4308_0
  - wheel=0.45.1=py39h06a4308_0
  - xz=5.6.4=h5eee18b_1
  - zlib=1.2.13=h5eee18b_1
  - pip:
      - alabaster==0.7.16
      - anyio==4.9.0
      - anytree==2.12.1
      - argon2-cffi==23.1.0
      - argon2-cffi-bindings==21.2.0
      - arrow==1.3.0
      - asttokens==3.0.0
      - async-lru==2.0.5
      - attrs==25.3.0
      - autograd==1.7.0
      - babel==2.17.0
      - beautifulsoup4==4.13.3
      - black==25.1.0
      - bleach==6.2.0
      - certifi==2025.1.31
      - cffi==1.17.1
      - charset-normalizer==3.4.1
      - click==8.1.8
      - comm==0.2.2
      - contourpy==1.3.0
      - cycler==0.12.1
      - debugpy==1.8.13
      - decorator==5.2.1
      - defusedxml==0.7.1
      - docutils==0.21.2
      - executing==2.2.0
      - fastjsonschema==2.21.1
      - flake8==7.2.0
      - fonttools==4.56.0
      - fqdn==1.5.1
      - guzzle-sphinx-theme==0.7.11
      - h11==0.14.0
      - httpcore==1.0.7
      - httpx==0.28.1
      - idna==3.10
      - imagesize==1.4.1
      - importlib-metadata==8.6.1
      - importlib-resources==6.5.2
      - ipykernel==6.29.5
      - ipython==8.18.1
      - ipywidgets==8.1.5
      - isoduration==20.11.0
      - jedi==0.19.2
      - jinja2==3.1.6
      - json5==0.10.0
      - jsonpointer==3.0.0
      - jsonschema==4.23.0
      - jsonschema-specifications==2024.10.1
      - jupyter==1.1.1
      - jupyter-client==8.6.3
      - jupyter-console==6.6.3
      - jupyter-core==5.7.2
      - jupyter-events==0.12.0
      - jupyter-lsp==2.2.5
      - jupyter-server==2.15.0
      - jupyter-server-terminals==0.5.3
      - jupyterlab==4.3.6
      - jupyterlab-pygments==0.3.0
      - jupyterlab-server==2.27.3
      - jupyterlab-widgets==3.0.13
      - kiwisolver==1.4.7
      - markupsafe==3.0.2
      - matplotlib==3.9.4
      - matplotlib-inline==0.1.7
      - mccabe==0.7.0
      - mistune==3.1.3
      - mypy-extensions==1.0.0
      - nbclient==0.10.2
      - nbconvert==7.16.6
      - nbformat==5.10.4
      - nest-asyncio==1.6.0
      - notebook==7.3.3
      - notebook-shim==0.2.4
      - numpy==2.0.2
      - overrides==7.7.0
      - pandas==2.2.3
      - pandocfilters==1.5.1
      - parso==0.8.4
      - pathspec==0.12.1
      - pexpect==4.9.0
      - pillow==11.1.0
      - platformdirs==4.3.7
      - prometheus-client==0.21.1
      - prompt-toolkit==3.0.50
      - psutil==7.0.0
      - ptyprocess==0.7.0
      - pure-eval==0.2.3
      - pycodestyle==2.13.0
      - pycparser==2.22
      - pyflakes==3.3.1
      - pygments==2.19.1
      - pyparsing==3.2.3
      - python-dateutil==2.9.0.post0
      - python-json-logger==3.3.0
      - pytz==2025.2
      - pyyaml==6.0.2
      - pyzmq==26.3.0
      - referencing==0.36.2
      - requests==2.32.3
      - rfc3339-validator==0.1.4
      - rfc3986-validator==0.1.1
      - rpds-py==0.24.0
      - scikit-fem==10.0.2
      - scipy==1.13.1
      - send2trash==1.8.3
      - six==1.17.0
      - sniffio==1.3.1
      - snowballstemmer==2.2.0
      - soupsieve==2.6
      - sphinx==7.4.7
      - sphinxcontrib-applehelp==2.0.0
      - sphinxcontrib-devhelp==2.0.0
      - sphinxcontrib-htmlhelp==2.1.0
      - sphinxcontrib-jsmath==1.0.1
      - sphinxcontrib-qthelp==2.0.0
      - sphinxcontrib-serializinghtml==2.0.0
      - stack-data==0.6.3
      - terminado==0.18.1
      - tinycss2==1.4.0
      - tornado==6.4.2
      - traitlets==5.14.3
      - types-python-dateutil==2.9.0.20241206
      - typing-extensions==4.13.0
      - tzdata==2025.2
      - uri-template==1.3.0
      - urllib3==2.3.0
      - wcwidth==0.2.13
      - webcolors==24.11.1
      - webencodings==0.5.1
      - websocket-client==1.8.0
      - widgetsnbextension==4.0.13
      - zipp==3.21.0
prefix: /opt/conda/envs/PyBaMM

tests/unit/test_logger.py::TestLogger::test_logger
tests/unit/test_processed_variable.py::TestProcessedVariable::test_call_failure tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_var_1D_interpolation tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_var_2D_interpolation tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_var_2Dspace_scikit_interpolation tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_var_3D_interpolation tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_var_3D_r_first_dimension tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_var_3D_scikit_interpolation tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_variable_1D tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_variable_2D tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_variable_2D_unknown_domain tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_variable_2Dspace_scikit tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_variable_3D_scikit tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_variable_3D_x_r tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_variable_3D_x_z tests/unit/test_processed_variable.py::TestProcessedVariable::test_processed_variable_ode_pde_solution
pybamm/__init__.py pybamm/logger.py pybamm/quick_plot.py CHANGELOG.md pybamm/processed_variable.py
pybamm/__init__.py pybamm/logger.py pybamm/quick_plot.py CHANGELOG.md pybamm/processed_variable.py