first outbreak since the initial in 07, been on acyclo bid

so, how come I have a new out break?  I have a male partner who thought he had athletes foot and the md even told him he did...right....we don't use a condom because we figure we both have it and don't have sex during an outbreak.  This is my first outbreak since the initial one last year.  I'm on suppressive drugs, bid, I did have a knee injury a month ago and a sick dog causing stess in my life.  How much could that have contributed to my new outbeak?  My partner and I have sex about once a week. 

Has ANY women gotten a lesion the size of a marble?  it stings when I pee and barely wipe but then settles down for most of the day.  Why is it so big?