Changing the channel sorted the TTS-1.
It looks like SPLAT isn't loading up some of my old projects properly, so channel is sometimes going missing, pan is sometimes set to hard left, volume set to 0 etc. I've not seen bank select or program changes getting corrupted so far. Ensuring the others are all set seems to fix it.
The S-YXG50 is still problematic in that although it now accepts the bank select/program changes, there's no way of forcing a patch list - so I'm left with using numbers. As a workaround, I've set one of my loopback devices to the XG patchlist and I can toggle back and forth between the MIDI outs (i.e. choose the program with the track set to midiLoop1, then swap it back to S-YXG50 when I play). Having the ability to use .ins definitions on the VST itself would be really useful.
I did try toggling the "Translate Bank/Program Changes" setting, but it didn't seem to do much with these VSTs. I suspect it would have a greater effect on others.
I'm trying to go pretty much vst only and retire my hardware synths, so I've been going through all my other hardware and sampling my favourite sounds using SampleRobot. The instrument copier function on this is fantastic: I give it a patch list and basic loop settings, go through and change the settings for the one-shot type instruments / really complex pads, and let it do its thing. It takes literally hours (around 30 hours for the last synth I did), but the results are really good.
I've ended up using sf2 format (out of convenience more than anything) using SampleLord as the host. I could have used Kontakt or Dimension Pro/Rapture with sfz, but having all the separate samples is unmanagable for the amount of sounds I have (I've got at least 16 hardware synths to sample).
For the sampled sounds it's easy as I just load the relevant soundfont and go with it.
Most of the XG based stuff I have are just 8 or 16 bar sketches, so although it's a bit of a pain at the moment, moving forward I'll probably convert them all to MIDI clips and start using them from the media browser.
M.