Hello Marc,

> Can you try feeding a message causing this error to stdin of exim -d
> [EMAIL PROTECTED] and post the resulting debug output
> here, preferably without obfuscation?

here we go, unnecessary and some internal parts removed:

Exim version 4.50 uid=0 gid=0 pid=14841 D=fbb95cfd
Berkeley DB: Sleepycat Software: Berkeley DB 4.2.52: (December  3, 2003)
Support for: iconv() IPv6 PAM Perl GnuTLS Content_Scanning Old_Demime
Lookups: lsearch wildlsearch nwildlsearch iplsearch cdb dbm dbmnz dnsdb dsearch 
ldap ldapdn ldapm mysql nis nis0 passwd pgsql
Authenticators: cram_md5 cyrus_sasl plaintext spa
Routers: accept dnslookup ipliteral iplookup manualroute queryprogram redirect
Transports: appendfile/maildir/mailstore/mbx autoreply lmtp pipe smtp
Fixed never_users: 0
changed uid/gid: forcing real = effective
  uid=0 gid=0 pid=14841
  auxiliary group list: <none>
lima03 in dns_ipv4_lookup? yes (matched "*")
configuration file is /etc/exim4/exim4.conf
log selectors = 00000ffc 00020800
trusted user
admin user
changed uid/gid: privilege not needed
  uid=8 gid=106 pid=14841
  auxiliary group list: <none>
finduser used cached passwd data for mail
finduser used cached passwd data for mail
user name "root" extracted from gecos field "root"
originator: uid=0 gid=0 login=root name=root
sender address = [EMAIL PROTECTED]
set_process_info: 14841 accepting a local non-SMTP message from <[EMAIL 
PROTECTED]>
spool directory space = .....
log directory space = .....
Sender: [EMAIL PROTECTED]
Recipients:
  [EMAIL PROTECTED]
search_tidyup called
>>Headers received:
Return-Path: <[EMAIL PROTECTED]>
Received: .....
Date: Fri, 6 Jan 2006 20:08:52 +0100
From: =?iso-8859-1?Q?Florian_Mei=DFner?= <[EMAIL PROTECTED]>
To: Andreas Edler <[EMAIL PROTECTED]>
Subject: Re: Bug#346260: exim4: autoreply problem with $reply_address and 
non-7bit chars
Message-ID: <[EMAIL PROTECTED]>
References: <[EMAIL PROTECTED]>
Mime-Version: 1.0
Content-Type: text/plain; charset=us-ascii
Content-Disposition: inline
In-Reply-To: <[EMAIL PROTECTED]>
User-Agent: Mutt/1.5.9i

address match: [EMAIL PROTECTED] pattern=abuse@(.*)
[EMAIL PROTECTED] in "abuse@(.*)"? no (end of list)
address match: [EMAIL PROTECTED] [EMAIL PROTECTED]
destination.addre.ss in "*"? yes (matched "*")
[EMAIL PROTECTED] in "[EMAIL PROTECTED]"? yes (matched "[EMAIL PROTECTED]")
search_open: mysql "NULL"
search_find: file="NULL"
  key="....." partial=-1 affix=NULL starflags=0
LRU list:
internal_search_find: file="NULL"
  type=mysql key="....."
database lookup required for .....
MYSQL query: .....
MYSQL new connection: host=..... port=0 socket=NULL database=..... user=exim
MYSQL: no data found
lookup failed
rewritten sender = [EMAIL PROTECTED]
rewrite_one_header: type=F:
  From: =?iso-8859-1?Q?Florian_Mei=DFner?= <[EMAIL PROTECTED]>
rewrite_one_header: type=T:
  To: Andreas Edler <[EMAIL PROTECTED]>
search_tidyup called
close MYSQL connection: ...../...../exim
>>Headers after rewriting and local additions:
* Return-Path: <[EMAIL PROTECTED]>
P Received: .....
  Date: Fri, 6 Jan 2006 20:08:52 +0100
F From: =?iso-8859-1?Q?Florian_Mei=DFner?= <[EMAIL PROTECTED]>
T To: Andreas Edler <[EMAIL PROTECTED]>
  Subject: Re: Bug#346260: exim4: autoreply problem with $reply_address and 
non-7bit chars
I Message-ID: <[EMAIL PROTECTED]>
  References: <[EMAIL PROTECTED]>
  Mime-Version: 1.0
  Content-Type: text/plain; charset=us-ascii
  Content-Disposition: inline
  In-Reply-To: <[EMAIL PROTECTED]>
  User-Agent: Mutt/1.5.9i

Data file written for message 1EvBpw-0003rN-Lv
>>Generated Received: header line
P Received: from root by lima03.sserv.de (Exim 4.50) with local
        for <[EMAIL PROTECTED]>
        id 1EvBpw-0003rN-Lv; Sat, 07 Jan 2006 12:02:20 +0100
calling local_scan(); timeout=300
local_scan() returned 0 NULL
Writing spool header file
Size of headers = 1014
LOG: MAIN
  <= [EMAIL PROTECTED] U=root P=local S=1915 [EMAIL PROTECTED]
search_tidyup called
exec /usr/sbin/exim4 -d=0xfbb95cfd -Mc 1EvBpw-0003rN-Lv
search_tidyup called
>>>>>>>>>>>>>>>> Exim pid=14841 terminating with rc=0 >>>>>>>>>>>>>>>>
Exim version 4.50 uid=8 gid=106 pid=14870 D=fbb95cfd
Berkeley DB: Sleepycat Software: Berkeley DB 4.2.52: (December  3, 2003)
Support for: iconv() IPv6 PAM Perl GnuTLS Content_Scanning Old_Demime
Lookups: lsearch wildlsearch nwildlsearch iplsearch cdb dbm dbmnz dnsdb dsearch 
ldap ldapdn ldapm mysql nis nis0 passwd pgsql
Authenticators: cram_md5 cyrus_sasl plaintext spa
Routers: accept dnslookup ipliteral iplookup manualroute queryprogram redirect
Transports: appendfile/maildir/mailstore/mbx autoreply lmtp pipe smtp
Fixed never_users: 0
changed uid/gid: forcing real = effective
  uid=0 gid=106 pid=14870
  auxiliary group list: <none>
lima03 in dns_ipv4_lookup? yes (matched "*")
configuration file is /etc/exim4/exim4.conf
log selectors = 00000ffc 00020800
trusted user
admin user
skipping ACL configuration - not needed
finduser used cached passwd data for mail
finduser used cached passwd data for mail
set_process_info: 14870 delivering specified messages
set_process_info: 14870 delivering 1EvBpw-0003rN-Lv
reading spool file 1EvBpw-0003rN-Lv-H
user=root uid=0 gid=0 [EMAIL PROTECTED]
sender_local=0 ident=root
Non-recipients:
Empty Tree
---- End of tree ----
recipients_count=1
body_linecount=20 message_linecount=21
Delivery address list:
  [EMAIL PROTECTED] 
locking /var/spool/exim/db/retry.lockfile
locked /var/spool/exim/db/retry.lockfile
opened hints database /var/spool/exim/db/retry: flags=0
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
Considering: [EMAIL PROTECTED]
unique = [EMAIL PROTECTED]
dbfn_read: key=R:destination.addre.ss
dbfn_read: key=R:[EMAIL PROTECTED]
no domain retry record
no address retry record
[EMAIL PROTECTED]: queued for routing
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
routing [EMAIL PROTECTED]
--------> domainlist router <--------
local_part=email domain=destination.addre.ss
checking domains
.....
domainlist router skipped: domains mismatch
--------> relaydomains router <--------
local_part=email domain=destination.addre.ss
checking domains
.....
relaydomains router skipped: domains mismatch
--------> lookuphost router <--------
local_part=email domain=destination.addre.ss
checking domains
.....
lookuphost router skipped: domains mismatch
--------> autoreply router <--------
local_part=email domain=destination.addre.ss
checking domains
search_open: mysql "NULL"
  cached open
search_find: file="NULL"
  key="SELECT DISTINCT domain ....." partial=-1 affix=NULL starflags=0
LRU list:
internal_search_find: file="NULL"
  type=mysql key="SELECT DISTINCT domain ....."
database lookup required for SELECT DISTINCT domain .....
MYSQL query: SELECT DISTINCT domain .....
MYSQL using cached connection for ...../...../exim
lookup yielded: destination.addre.ss
destination.addre.ss in "destination.addre.ss"? yes (matched 
"destination.addre.ss")
checking senders
address match: [EMAIL PROTECTED] [EMAIL PROTECTED]
sender.addre.ss in "*"? yes (matched "*")
[EMAIL PROTECTED] in "[EMAIL PROTECTED]"? yes (matched "[EMAIL PROTECTED]")
checking "condition"
search_open: mysql "NULL"
  cached open
search_find: file="NULL"
  key="SELECT localpart ....." partial=-1 affix=NULL starflags=0
LRU list:
internal_search_find: file="NULL"
  type=mysql key="SELECT localpart ....."
database lookup required for SELECT localpart .....
MYSQL query: SELECT localpart .....
MYSQL using cached connection for ...../...../exim
lookup yielded: email
calling autoreply router
autoreply router called for [EMAIL PROTECTED]
  domain = destination.addre.ss
set transport vacation_transport
queued for vacation_transport transport: local_part = email
domain = destination.addre.ss
  errors_to=NULL
  domain_data=NULL localpart_data=NULL
routed by autoreply router (unseen)
  envelope to: [EMAIL PROTECTED]
  transport: vacation_transport
"unseen" set: replicated [EMAIL PROTECTED]
locking /var/spool/exim/db/retry.lockfile
locked /var/spool/exim/db/retry.lockfile
opened hints database /var/spool/exim/db/retry: flags=0
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
Considering: [EMAIL PROTECTED]
unique = [EMAIL PROTECTED]
dbfn_read: key=R:destination.addre.ss
dbfn_read: key=R:[EMAIL PROTECTED]
no domain retry record
no address retry record
[EMAIL PROTECTED]: queued for routing
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
routing [EMAIL PROTECTED]
--------> alias_domain router <--------
local_part=email domain=destination.addre.ss
.....
alias_domain router declined for [EMAIL PROTECTED]
--------> virtual_localuser router <--------
local_part=email domain=destination.addre.ss
checking domains
search_open: mysql "NULL"
  cached open
search_find: file="NULL"
  key="SELECT DISTINCT domain ....." partial=-1 affix=NULL starflags=0
LRU list:
internal_search_find: file="NULL"
  type=mysql key="SELECT DISTINCT domain ....."
cached data used for lookup of SELECT DISTINCT domain .....
lookup yielded: destination.addre.ss
destination.addre.ss in "destination.addre.ss"? yes (matched 
"destination.addre.ss")
calling virtual_localuser router
virtual_localuser router called for [EMAIL PROTECTED]
  domain = destination.addre.ss
set transport virtual_local_delivery
queued for virtual_local_delivery transport: local_part = email
domain = destination.addre.ss
  errors_to=NULL
  domain_data=NULL localpart_data=NULL
routed by virtual_localuser router
  envelope to: [EMAIL PROTECTED]
  transport: virtual_local_delivery
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
After routing:
  Local deliveries:
    [EMAIL PROTECTED]
    [EMAIL PROTECTED]
  Remote deliveries:
  Failed addresses:
  Deferred addresses:
search_tidyup called
close MYSQL connection: ...../...../exim
>>>>>>>>>>>>>>>> Local deliveries >>>>>>>>>>>>>>>>
--------> [EMAIL PROTECTED] <--------
.....
virtual_local_delivery transport returned OK for [EMAIL PROTECTED]
post-process [EMAIL PROTECTED] (0)
[EMAIL PROTECTED] delivered
LOG: MAIN
  => email <[EMAIL PROTECTED]> R=virtual_localuser T=virtual_local_delivery
--------> [EMAIL PROTECTED] <--------
locking /var/spool/exim/db/retry.lockfile
locked /var/spool/exim/db/retry.lockfile
opened hints database /var/spool/exim/db/retry: flags=0
dbfn_read: key=T:[EMAIL PROTECTED]
no retry record exists
search_tidyup called
changed uid/gid: local delivery to email <[EMAIL PROTECTED]> 
transport=vacation_transport
  uid=8 gid=8 pid=14878
  auxiliary group list: <none>
  home=NULL current=/
set_process_info: 14878 delivering 1EvBpw-0003rN-Lv to email using 
vacation_transport
vacation_transport transport entered
taking data from transport
search_tidyup called
vacation_transport transport returned FAIL for [EMAIL PROTECTED]
post-process [EMAIL PROTECTED] (2)
LOG: MAIN
  ** [EMAIL PROTECTED] R=autoreply T=vacation_transport: Expansion of 
"${reply_address}" in vacation_transport transport contains non-printing 
character 195
>>>>>>>>>>>>>>>> deliveries are done >>>>>>>>>>>>>>>>
changed uid/gid: post-delivery tidying
  uid=8 gid=106 pid=14870
  auxiliary group list: <none>
set_process_info: 14870 tidying up after delivering 1EvBpw-0003rN-Lv
Processing retry items
Succeeded addresses:
[EMAIL PROTECTED]: no retry items
[EMAIL PROTECTED]: no retry items
Failed addresses:
[EMAIL PROTECTED]: no retry items
[EMAIL PROTECTED]: no retry items
Deferred addresses:
end of retry processing
processing failed address [EMAIL PROTECTED]
exec /usr/sbin/exim4 -d=0xfbb95cfd -t -oem -oi -f <> -E1EvBpw-0003rN-Lv
sending error message to: [EMAIL PROTECTED]
writing data block fd=8 size=1943 timeout=0
Exim version 4.50 uid=8 gid=106 pid=14879 D=fbb95cfd
Berkeley DB: Sleepycat Software: Berkeley DB 4.2.52: (December  3, 2003)
Support for: iconv() IPv6 PAM Perl GnuTLS Content_Scanning Old_Demime
Lookups: lsearch wildlsearch nwildlsearch iplsearch cdb dbm dbmnz dnsdb dsearch 
ldap ldapdn ldapm mysql nis nis0 passwd pgsql
Authenticators: cram_md5 cyrus_sasl plaintext spa
Routers: accept dnslookup ipliteral iplookup manualroute queryprogram redirect
Transports: appendfile/maildir/mailstore/mbx autoreply lmtp pipe smtp
Fixed never_users: 0
changed uid/gid: forcing real = effective
  uid=0 gid=106 pid=14879
  auxiliary group list: <none>
lima03 in dns_ipv4_lookup? yes (matched "*")
configuration file is /etc/exim4/exim4.conf
log selectors = 00000ffc 00020800
trusted user
admin user
changed uid/gid: privilege not needed
  uid=8 gid=106 pid=14879
  auxiliary group list: <none>
finduser used cached passwd data for mail
finduser used cached passwd data for mail
originator: uid=8 gid=106 login=mail name=
sender address = 
set_process_info: 14879 accepting a local non-SMTP message from <>
spool directory space = .....
log directory space = .....
Sender: 
search_tidyup called
>>Headers received:
X-Failed-Recipients: [EMAIL PROTECTED]
Auto-Submitted: auto-generated
From: Mail Delivery System <[EMAIL PROTECTED]>
To: [EMAIL PROTECTED]
Subject: Mail delivery failed: returning message to sender

>>Headers after rewriting and local additions:
  X-Failed-Recipients: [EMAIL PROTECTED]
  Auto-Submitted: auto-generated
F From: Mail Delivery System <[EMAIL PROTECTED]>
T To: [EMAIL PROTECTED]
  Subject: Mail delivery failed: returning message to sender
I Message-Id: <[EMAIL PROTECTED]>
  Date: Sat, 07 Jan 2006 12:02:20 +0100

Data file written for message 1EvBq0-0003rz-I4
>>Generated Received: header line
P Received: from mail by lima03.sserv.de (Exim 4.50) with local
        for <[EMAIL PROTECTED]>
        id 1EvBq0-0003rz-I4; Sat, 07 Jan 2006 12:02:20 +0100
calling local_scan(); timeout=300
local_scan() returned 0 NULL
Writing spool header file
Size of headers = 425
LOG: MAIN
  <= <> R=1EvBpw-0003rN-Lv U=mail P=local S=2775
search_tidyup called
exec /usr/sbin/exim4 -d=0xfbb95cfd -Mc 1EvBq0-0003rz-I4
search_tidyup called
>>>>>>>>>>>>>>>> Exim pid=14879 terminating with rc=0 >>>>>>>>>>>>>>>>
[EMAIL PROTECTED]: children all complete
Writing spool header file
Exim version 4.50 uid=8 gid=106 pid=14881 D=fbb95cfd
Berkeley DB: Sleepycat Software: Berkeley DB 4.2.52: (December  3, 2003)
Support for: iconv() IPv6 PAM Perl GnuTLS Content_Scanning Old_Demime
Lookups: lsearch wildlsearch nwildlsearch iplsearch cdb dbm dbmnz dnsdb dsearch 
ldap ldapdn ldapm mysql nis nis0 passwd pgsql
Authenticators: cram_md5 cyrus_sasl plaintext spa
Routers: accept dnslookup ipliteral iplookup manualroute queryprogram redirect
Transports: appendfile/maildir/mailstore/mbx autoreply lmtp pipe smtp
Fixed never_users: 0
changed uid/gid: forcing real = effective
  uid=0 gid=106 pid=14881
  auxiliary group list: <none>
lima03 in dns_ipv4_lookup? yes (matched "*")
configuration file is /etc/exim4/exim4.conf
log selectors = 00000ffc 00020800
trusted user
admin user
skipping ACL configuration - not needed
finduser used cached passwd data for mail
finduser used cached passwd data for mail
set_process_info: 14881 delivering specified messages
set_process_info: 14881 delivering 1EvBq0-0003rz-I4
reading spool file 1EvBq0-0003rz-I4-H
user=mail uid=8 gid=106 sender=
sender_local=0 ident=mail
Non-recipients:
Empty Tree
---- End of tree ----
recipients_count=1
body_linecount=57 message_linecount=10
Delivery address list:
  [EMAIL PROTECTED] 
locking /var/spool/exim/db/retry.lockfile
locked /var/spool/exim/db/retry.lockfile
opened hints database /var/spool/exim/db/retry: flags=0
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
Considering: [EMAIL PROTECTED]
unique = [EMAIL PROTECTED]
dbfn_read: key=R:sender.addre.ss
dbfn_read: key=R:[EMAIL PROTECTED]
no domain retry record
no address retry record
[EMAIL PROTECTED]: queued for routing
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
routing [EMAIL PROTECTED]
--------> domainlist router <--------
local_part=source domain=sender.addre.ss
checking domains
search_open: mysql "NULL"
search_find: file="NULL"
  key="SELECT DISTINCT domain ....." partial=-1 affix=NULL starflags=0
LRU list:
internal_search_find: file="NULL"
  type=mysql key="SELECT DISTINCT domain ....."
database lookup required for SELECT DISTINCT domain .....
MYSQL query: SELECT DISTINCT domain .....
MYSQL new connection: host=..... port=0 socket=NULL database=..... user=exim
Size of headers = 1014
LOG: MAIN
  Completed
end delivery of 1EvBpw-0003rN-Lv
search_tidyup called
search_tidyup called
>>>>>>>>>>>>>>>> Exim pid=14870 terminating with rc=0 >>>>>>>>>>>>>>>>
MYSQL: no data found
lookup failed
search_open: mysql "NULL"
  cached open
search_find: file="NULL"
  key="SELECT domain ....." partial=-1 affix=NULL starflags=0
LRU list:
internal_search_find: file="NULL"
  type=mysql key="SELECT domain ...."
database lookup required for SELECT domain .....
MYSQL query: SELECT domain .....
MYSQL using cached connection for ...../...../exim
MYSQL: no data found
lookup failed
sender.addre.ss in "....."? no (end of list)
sender.addre.ss in "! +local_domains"? yes (end of list)
calling domainlist router
domainlist router called for [EMAIL PROTECTED]
  domain = sender.addre.ss
search_open: lsearch "/etc/exim4/paths/paths-smtp"
search_find: file="/etc/exim4/paths/paths-smtp"
  key="sender.addre.ss" partial=1 affix=*. starflags=0
LRU list:
  :/etc/exim4/paths/paths-smtp
  End
internal_search_find: file="/etc/exim4/paths/paths-smtp"
  type=lsearch key="sender.addre.ss"
file lookup required for sender.addre.ss
  in /etc/exim4/paths/paths-smtp
.....
set transport remote_smtp
.....
routed by domainlist router
  envelope to: [EMAIL PROTECTED]
  transport: remote_smtp
  host .....
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
After routing:
  Local deliveries:
  Remote deliveries:
    [EMAIL PROTECTED]
  Failed addresses:
  Deferred addresses:
search_tidyup called
close MYSQL connection: .....
>>>>>>>>>>>>>>>> Remote deliveries >>>>>>>>>>>>>>>>
.....
LOG: MAIN
  => [EMAIL PROTECTED] R=domainlist T=remote_smtp H=.....
>>>>>>>>>>>>>>>> deliveries are done >>>>>>>>>>>>>>>>
changed uid/gid: post-delivery tidying
  uid=8 gid=106 pid=14881
  auxiliary group list: <none>
set_process_info: 14881 tidying up after delivering 1EvBq0-0003rz-I4
Processing retry items
Succeeded addresses:
[EMAIL PROTECTED]: no retry items
Failed addresses:
Deferred addresses:
end of retry processing
LOG: MAIN
  Completed
end delivery of 1EvBq0-0003rz-I4
search_tidyup called
search_tidyup called
>>>>>>>>>>>>>>>> Exim pid=14881 terminating with rc=0 >>>>>>>>>>>>>>>>


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