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There is no reason that I should go into a Frontline Roulette, change jobs to fill the healer role, and then when I come out *not* be able to switch back to the job I was on previously. I have gained no items, I have changed no items. My inventory has changed in no way.
I... personally never had this issue? I am actually confused by this, even if I somehow lost the weapon I had on that gearset, so long as I have a viable weapon for that Job, the game simply prompts me if I want to equip that weapon instead when I try to change, never have I been completely unable to change back to a gearset, unless I have no viable weapon at all.
The closest thing I can think of is that occasionally some actions will prevent you from changing gearsets, but you literally only have to wait one GCD for it to let you, I always assumed it's some sort of protection from errors happening, and waiting 3 seconds is no big deal.
The main cause of that for me that I've noticed is usually rings... If you have the same rings set on different fingers between two sets, the game can't just simply move your rings, it has to place them both in the armory and re-equip them.
The fix is to not have a full armory chest.
It's a consistent issue for me and revolves 95% of the time around changing jobs in Frontline. Literally *none* of my equipment changed, I moved nothing, I deleted nothing, I was exactly the same going into the instance as I was coming out, aside from swapping to Sage from Reaper. Randomly moving things around allowed me to fix it *somewhat* but I still had to redo my Red Mage Gearset for some reason.
Also, 'not having a full armory chest' isn't really a good solution when we have content that requires alternate sets of gear like Eureka, for example, couple with having effectively 33 jobs to keep gear for if you're an omni-player.
But FFXIV diehards will defend this game as hard as WoW diehards will complain about it, even when the complaint is legitimate.
For me, it used to be an issue because I like to hoard gear loots until I can't hold anymore so I can dump them all in one go in a single squadron seal sweetener window for better seal yields. Later I find out that by making sure all my rings are properly matched between shared gearsets (i.e. Gearset A equips Caster Ring X to left ring and Caster Ring Y to right ring), I stopped having this issue.
For some reason they get finnicky if you try to switch between gearsets that have differing rings on differing slot, i.e. Gearset A equips Caster Ring X to left ring and Caster Ring Y to right ring; Gearset B equips Caster Ring Y to left ring and Caster Ring X to right ring - yeah, they don't like that lol.
Until they do anything about it, I think that's all you can do + not stay on full inventory for long.