Providing I understand what you say correctly - I would be very worried. If you remove the main Neutral wire you still have working lights !?!
This means that the return path is via Earth somewhere in the property. In the interests of safety this should be resolved immediately.
No wonder the RCD tripped when you installed the new consumer unit - it compares the current in the Line and Neutral and wants them to be within 30mA of one another If current is running to earth then the RCD will always trip - as it should.
Quite why you wired the consumer unit to a plug and tried it in various sockets I'm not sure. Presumably there was no output load on it and no current being drawn - so the RCD will never trip.
Get a Sparky in soon.
Peccavi
October 2008