In the presence of rate constraints in actuator, design of cascade controller based on the primary controller conditional integration can result into closed-loop system oscillations. Stability analysis, performed by the describing function technique and confirmed by simulation, demonstrates that the solution based on the Anti-Reset Windup Cascade Control System (ARW CCS) structure is successful. Design and tuning of the ARW CCS secondary controller is a standard ARW single-input single-output problem. In the present paper tuning is proposed for the ARW CCS primary controller. For the serial process modeling simple rules are derived and confirmed by experimental results, obtained on a drum type boiler of a 210 MWe lignite coal fired unit. General design of the ARW CCS is based on the parallel process modeling and optimization of the primary controller. Optimization is performed in the frequency domain, under constraints on the maximum sensitivity, multiplicative uncertainty bound and sensitivity to measurement noise. Simulation and experimental results on a laboratory thermal plant demonstrate effectiveness of the proposed optimization. (C) 2014 Elsevier Ltd. All rights reserved.