Bulk heterojunction organic solar cell devices were fabricated using the spray deposited poly [N-9″-hepta-decanyl-2,7-carbazole-alt-5,5-(4′, 7′-di-2-thienyl-2′,1′,3′-benzothiadiazole)]/[6,6] -phenyl-C61-butyric acid methyl ester blend active layer. The spray coating parameters such as spraying time, substrate-nozzle distance for the deposition of active layers were analyzed. Optical absorption of the active layers was analyzed using UV-visible spectral studies in the wavelength range from 300 to 800 nm. The surface morphology of the active layers deposited with different parameters was examined using atomic force microscopy. Surface morphology of the active layers deposited with the substrate-nozzle distance of 20 cm and for 20 s shows smooth morphology with peak-valley value of 4 nm. The devices fabricated using the selected active layer show overall power conversion efficiency of 1.08%. © 2011 Elsevier B.V. All rights reserved.