It can be that you are sewing too fast for the thread and it jumps away from the sensor and gives a false reading, try slowing down.
Also I would do the usual checks for lint, change thread, needle, rethread etc.,
I had the warning problem that drove me crazy for months and my machine went back for a couple of times. In the end I worked out it was caused by me forgetting on a number of occasions to put the thread guide up and the thread overtensions and snaps and I think this upsets the sensor somehow. Now I am so careful to never do that and it's been fine for months. I am madly looking for some wood to touch now.
This my thread I was given good advice [url]forum/domestic-sewing-machines/5556-top-thread-broken-warning-pfaff-help[/url]