Specific hero questions

Going through the character sheets:

• Why is Absolute Zero's Cold Burn a Green ability?  It seems like it's strictly inferior to a basic action unless he's in Yellow for the Null-Point Calibrator to kick in.
• AZ's Principle of Cold ability says that it has to be a "challenge involving cold."  Does that mean the challenge has to already be cold-related?  Or can just AZ's solution to the problem be cold-related?  If the latter, that seems too easy--AZ solves most problems using cold, one way or another.
• If Bunker is Out in Out of Suit "mode", what can he do, if anything?
• Bunker doesn't seem to have very many options at the beginning of a scene.  He can change modes, take basic actions and... that's it?  Everyone else seems to have at least one Green ability that they could use in most situations.  Bunker's only option locks him into a limited (though potent) mode, which, if he uses it, means he's probably doing nothing but Boosting for the first 3 rounds (Mode Shift to enter Utility Mode, Uplink Upgrade while he's in it because that's the only reason to ever be in Utility Mode, then another Mode Shift).  It's very like card game Bunker but doesn't seem like a good plan most of the time.
• When Bunker is Out of Suit, how does he get back in the suit?  He can't take the Mode Shift action.  Is that just a normal action that requires no roll?
• Legacy's character sheet mentions damage types (physical and energy).  However, nothing in the rules mentions damage types.  Are these just ruled ad-hoc every time?  What are the damage types?  The "Attack" section of the rules mentions "physical," "emotional," and "mental" damage, which I ignored as flavor until I saw Legacy's character sheet.  Does that mean that someone with a less physical power/quality set can make an "emotional" attack as a basic action?
• What does "Mind Over Matter" mean as one of Tachyon's powers?  I usually see that term used to describe someone exceeding the apparent physical limits of their body through concentration, but that doesn't seem Tachyon's style--she's very aware of the physical limits of her body and I wouldn't think she'd be interested in froo-froo meditation and focus techniques.
• I don't understand Unity's "Turret" upgrade at all.  How do you split a die?  Is it making two separate attacks?
• Some of the upgrades seem really costly, given that a minion is highly likely to get destroyed before it can take a single action.  Am I missing something?
• Do you have to justify why the bonus you're discarding applies to the upgrade you're creating?  (This would apply to Bunker's Sattelite Recall as well.)

I can't answer anything definitively, but: 

• Bunker still has access to "Power Suit," while in Operations Mode (which he starts in.) From previous conversations (maybe in the Boards Alive recording?) it was reasoned that anything reasonable to be in the Power Suit is. So he can still do quite a lot of attacking, just not the specialized attacking of Grenade Launcher, etc. 
• I think "Out of Suit Mode" is there to be a mechanical backing in case the story demands he leave his suit. He still has access to the Riot Cannon, of course. 
• I intuited the damage types to be ad hoc and up to the discretion of the GM. 
• "Mind over Matter" can also be used for overpowering your body through focus and discipline. It's an analogue to "Pushing the Limits," I think. On her opposite page it suggests Mind over Matter is "Tachyon's attitude towards life in general," which I guess means she thinks anything can be overcome through thought? I'm not entirely sure. 
• Turret mode: I believe it is making two separate attacks. 
• I don't think a minion is that likely to die: If you order characters correctly Unity could act towards the end of one round, then the beginning of the following (which isn't unlikely at all,) and if a GM is reasonable they probably won't destroy the golem right off the bat. 
• I believe they mention in the general rules that you do have to have a good reason for why your bonus is useful/how it is created. 

If I remember correctly from the BAP SC RPG, hosted by Christopher, the Giant Tech-rantula stayed around for the entire fight with the Spider-bots. It seems like they woud stay around unless killed or the battle is over. Is this not true?

Yes, it would stick around until destroyed or the battle was over, but a single successful hit destroys it.

So there isn't a diff die size for each minion type, or are you just saying it's based off the luck of the attack roll? The latter seems fine to me, but...

-goes to check booklet again because if they're all d4s, that's kinda lame. -

The minions come in different sizes based on the result of Unity's roll to create them, but even if she gets a d12 one, it still goes down instantly if any old roll beats its defense roll.  A d4 minion attacks it with a 4, the bot rolls a 3, it's dead.  It's not likely, but it'll still happen often enough to be frustrating unless the heroes very carefully plan their turns so that no villains get their turns in between Unity's two turns.

Cold Burn would be worthwhile if you want to get into your Yellow zone, which has a better Status die. (AZ seems to care about health differently than a lot of other characters.)

Don't forget how Modular Realignment gives a Boost any time AZ changes zones, making yo-yoing a much more desirable prospect. (Though I wonder how that intersects with the Scene Tracker.)

I wonder if the negatives on Cold Burn helped AZ get such strong dice for everything.  It seemed like the green powers all had a minor boost, yellow had 2 boosts, and red had three.

I consider dice stats to work like this:

You have starting dice:  12, 12, 12, 10, 6.  You can split any of those dice except the 6.  Splittin a die makes it two dice of the next level.  For example, splitting a 12 yields two 10's.

You are required to provide die values for 3 status values, 4 powers, and 4 whatever the other is called.  However, you can have more of the last two by splitting your dice further.  The maximum values you can have and cover all 11 slots are:  12, 10, 10, 8, 8, 8, 8, 8, 6, 6, 6.

However, AZ has higher stats than this, with an extra 12, I think.  And Bunker has lower stats as he split sice and spent them to get his extra modes.