The intermittent crackling and static sounds could be caused by various factors, such as faulty components, loose connections, or even a grounding issue. Since you’ve already tried adjusting parameters and inspected the PCBs, I recommend seeking assistance from a qualified pedal technician. They have the expertise to diagnose and repair the specific problem, allowing you to continue enjoying your beloved pedal for years to come.
It seems like the expression pedal input on your Stereo Polyphase pedal is behaving strangely, only working with Control Voltages from devices that aren’t grounded via the earth pin of their mains plugs. This could be due to a possible issue with the socket’s ground connection. It’s likely that the socket may be missing its ground connection or has one when it shouldn’t. I recommend reaching out to the technician who repaired your pedal to have them check the ground connection on the expression pedal socket for proper configuration.
Best of luck with your modular synth system!