good to hear it's working for you now. Probably the bounces which you received were sent before the mod was installed, but received after. The mod needs to be installed before theemail is sent as the script attaches the header to the outgoing email.
The error you're getting is likely because you're server's using php5. This is easy to fix. As matter of fact, the new version i'll update it today will resolve this. You could easily fix it yourself by editing ezbounce.php file as follows:
Find:
PHP Code:
// process errors if there are any
$errors = array_merge($errors, $pmdm->errors);
Replace with:
PHP Code:
// process errors if there are any
$errors = array_merge((array)$errors, $pmdm->errors);
should do the trick. The newest version has this fixed.