Hello. Did you patch old New Horizons client using PWI to EPW patch? It's not going to work...
The old EPW client is New Horizons version and the PWI to EPW patch can be used only for Eclipse/Elysium clients.
If you don't have such, then you should download our full client.
I suggest torrent, it is the most reliable option and can be paused and resumed at any time without getting corrupted.