Hi Scott, Silvertones may have momentarily forgotten your issue is with RB because this is the BB forum. But understood the issue may be related to this subject, and I do commiserate. Several of us have had HB issues in both programs.
I just opened RB for the first time since the 2010 upgrade, for some troubleshooting, and son-of-a-gun the upgrade overwrote my custom patches.ini file! Someone here wanna insist it's safe to install over a prior directory? (Luckily I have a backup.)
But you don't need a custom patches.ini file for TTS-1. It is GM2 compliant, and GM2 is in the factory ini file. So you just wanna make sure you've chosen that in the Patch Select dialog. Also in Options=>patch names. If you're going to use the TTS-1 a lot, might help to be familiar with it's higher bank architecture. Not sure why that MSB=121 was chosen for the GM2 higher bank spec, or even if that's an official spec, but the TTS-1 does appear compliant with it. (Creates havoc with my external synth when I forget to switch back from GM2 to the synth patch map

)
You may want to start a thread in the RB forum. Some points to consider:
1. Your midi files have patch changes in them, correct? Do they also have the bank controller events? You can check the Event list for each track and make sure the expected data are there. You can also use the midi monitor to confirm that they are being generated in real time. Note that you can have the midi monitor and the DXi interface both displayed while the song plays, so if you have a reproducible anomaly, you may be able to correlate the offending event(s) with the change in the track patch assignment in real time. When you have patch data in the sequence and also a track patch setting, be sure to understand which prevails. (I forget which at the moment, and the test midi file I'm using doesn't have patch changes in it.)
2. You are using RB as a straight sequencer for the midi, right? No BB track generation. Because if the latter, then a style is being invoked, and the style could be sending patch changes (depending on your pref settings).
3. In the midi monitor, you can filter for program change, CC0 and CC32, then right click on any given track and use the patch select dialog to understand if and when bank changes are sent as you make choices from the dialog. Notice that the bank controller changes are not sent until you make a selection from the "variations" box on the right side of that window. (This is flaky design IMHO. Given the complexity of these programs, and the variety of parameters that determine the patch change command structure, I believe bank controllers should
always be sent with a patch change. I've mentioned this to support before, but so far, we seem to have only partial implementation.)
None of this may relate directly to your problem, but it may help with a more focused diagnosis. Good luck, Ron
EDIT After reading the next couple posts. I should have said I'm still on XP SP3, so no 64 bit experience with the TTS-1. It does work for me in Sonar 7. Am waiting for new Win7 machine before installing Sonar 8.