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I don't think the setting of the player matters. That is just visual, since obviously you can change the role after a player has pitched and the tiredness will change instantly. I think the only thing that matters is whether the player starts the game or comes in as a reliever.
So go ahead and have your SP in a reliever role. He should get used based on what his rest% says when set to RP. It'll just be a little difficult for you to see if he's really to tired to pitch in relief or not.
If the AI is changing their roles to RP, you could use the strategy setting the force role as SP. They will be put into the rotation, unless you set multiple players to force start as SP and there isn't enough spots in the rotation for them all. So the AI will pick the 5 it wants and set the 6th to some relief role.
I'm playing OOTP 18, and I don't have this issue with the AI changing the role of a 6th+ SP in the bullpen, even when I tell them to sort the minor league. Maybe that's because I have the players locked to a league level, or because I'm set to control the lineups in the minors... I'm not sure.
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