I will not answer all of your questions but I will answer the ones I feel best able to... the AP is definitely worth the $600 it cost. It opens up the engine in the 1st, 2nd, and 3rd gear. The whole car seems to become more alive and responds to your foot much better than without the tune. If you doubt whether or not you want to be concerned about your warranty - then I have one word of advice, don't install the AP. It will be hard to go back to the stock car after you have done so. It changes the car that much. It's not a HUGE change, but it is noticeable and significant enough to be missed.
As for as warranty goes, that's a topic for debate. If something happens to your engine, and you have to take it the dealer, do you want to have to worry about whether or not they will look for a tune? If so, don't get it. People will assure you it can't be detected, and that may be the case, but in the end those same people who assure you it can't be detected sure as heck won't be there to pay for the repairs if the dealer does some how figure out you used a tune and decided to decline the repair. Nor will they be there to help you get through the fighting with the dealership that will ensue....it may not ever be an issue, those who assure you it can't be detected may be right, but when the car is kept stock, it's not a concern. When the car is modified, it is a concern. It's up to you decide if you want to be concerned or not.
In regards to the AP being too much for the engine? HIGHLY unlikely. This engine is definitely underrated from the factory. It's more than able to handle quite a bit more power without any internal modifications. This isn't uncommon. Manufacturers design and plan cars for their intended market and try not to provide too much to take away from other cars that offer more and sell at a higher price...they try to keep them within their respected target demography. That doesn't mean the engine isn't capable of much more. It just means the manufacturer did it's best to tune it from the factory so it's within that intended range (in the case of the Fiesta ST, it's the factory tune and small turbo)...short version, it's doubtful and very unlikely a OTS tune or any tune worth it's salt would ever be the real reason this engine decided to give up. You may be unfortunate enough to have a dud, shrug, who knows - but averaged across all the Fiesta ST engines, it's not likely to have ever been the OTS tune.
That's about all I can answer from my opinion and point of view. I personally chose to keep my car stock just because I never want to be in the situation of having to be worried should something happen and I have to take the car in to the dealer...